Methods for terminating olefin polymerizations

ABSTRACT

Catalyst deactivating agents and compositions containing catalyst deactivating agents are disclosed. These catalyst deactivating agents can be used in methods of controlling polymerization reactions, methods of terminating polymerization reactions, methods of operating polymerization reactors, and methods of transitioning between catalyst systems.

BACKGROUND OF THE INVENTION

There are various methods and materials that can be employed toterminate a polymerization reaction. For example, injections of largeamounts of water or isopropanol into a polymerization reactor ordownstream of the reactor can be used to terminate the polymerizationreaction. However, these methods and materials often can lead toexcessive cost, clean-up, and/or downtime.

It would be beneficial to develop new methods and materials that caneffectively terminate a polymerization reaction, either for rapidtermination in the polymerization reactor due to a process upset, or forneutralization of catalyst reactivity downstream of the reactor duringnormal polymer production, yet reduce the associated cost, clean-up, anddowntime. Accordingly, it is to these ends that the present disclosureis directed.

SUMMARY OF THE INVENTION

Methods of controlling a polymerization reaction in a polymerizationreactor system are disclosed herein. One such method can compriseintroducing a catalyst deactivating agent into the polymerizationreactor system to partially or completely terminate the polymerizationreaction. The catalyst deactivating agent can be introduced into apolymerization reactor within the polymerization reactor system, and/orthe catalyst deactivating agent can be introduced downstream of thepolymerization reactor. Consistent with embodiments disclosed herein,the catalyst deactivating agent can comprise a natural source oil, asiloxane, or a combination thereof.

Another method of controlling a polymerization reaction in apolymerization reactor system is provided, and in this embodiment, themethod can comprise:

-   -   (i) introducing a transition metal-based catalyst system, an        olefin monomer, and optionally an olefin comonomer into a        polymerization reactor within the polymerization reactor system;    -   (ii) contacting the transition metal-based catalyst system with        the olefin monomer and the optional olefin comonomer under        polymerization conditions to produce an olefin polymer; and    -   (iii) introducing a catalyst deactivating agent into the        polymerization reactor to partially or completely terminate the        polymerization reaction in the polymerization reactor.

Another method of controlling a polymerization reaction in apolymerization reactor system is provided, and in this embodiment, themethod can comprise:

-   -   (1) introducing a transition metal-based catalyst system, an        olefin monomer, and optionally an olefin comonomer into a        polymerization reactor within the polymerization reactor system;    -   (2) contacting the transition metal-based catalyst system with        the olefin monomer and the optional olefin comonomer under        polymerization conditions to produce an olefin polymer; and    -   (3) introducing a catalyst deactivating agent into the        polymerization reactor system downstream of the polymerization        reactor to completely terminate the polymerization reaction.

Another method of controlling a polymerization reaction in apolymerization reactor system is provided herein, and this method cancomprise:

-   -   (a) introducing a transition metal-based catalyst system, an        olefin monomer, and optionally an olefin comonomer into a        polymerization reactor within the polymerization reactor system;    -   (b) contacting the transition metal-based catalyst system with        the olefin monomer and the optional olefin comonomer under        polymerization conditions to produce an olefin polymer;    -   (c) monitoring a process variable to detect an undesired        condition in the polymerization reactor system; and    -   (d) when the undesired reaction condition has reached a        predetermined critical level, introducing a catalyst        deactivating agent into the polymerization reactor.

Yet, in another embodiment, a method of controlling a polymerizationreaction in a polymerization reactor system directed to transitioningbetween catalyst systems is provided. This method can comprise:

-   -   (A) introducing a first transition metal-based catalyst system,        a first olefin monomer, and optionally a first olefin comonomer        into a polymerization reactor in the polymerization reactor        system;    -   (B) contacting the first transition metal-based catalyst system        with the first olefin monomer and the optional first olefin        comonomer under polymerization conditions to produce a first        olefin polymer;    -   (C) discontinuing the introducing of the first transition        metal-based catalyst system into the polymerization reactor        before, during, or after a step of introducing a catalyst        deactivating agent into the polymerization reactor; and    -   (D) introducing a second transition metal-based catalyst system        into the polymerization reactor and contacting the second        transition metal-based catalyst system with a second olefin        monomer and optionally a second olefin comonomer under        polymerization conditions to produce a second olefin polymer.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 presents a plot of the reaction rate versus the reaction time forExample 1 and the addition of corn oil to a polymerization reactionusing a chromium-based catalyst system.

FIG. 2 presents a plot of the reaction rate versus the reaction time forExample 2 and the addition of corn oil to a polymerization reactionusing a chromium-based catalyst system.

FIG. 3 presents a plot of the reaction rate versus the reaction time forExample 3 and the addition of a polydimethylsiloxane to a polymerizationreaction using a chromium-based catalyst system.

DEFINITIONS

To define more clearly the terms used herein, the following definitionsare provided. Unless otherwise indicated, the following definitions areapplicable to this disclosure. If a term is used in this disclosure butis not specifically defined herein, the definition from the IUPACCompendium of Chemical Terminology, 2^(nd) Ed (1997) can be applied, aslong as that definition does not conflict with any other disclosure ordefinition applied herein, or render indefinite or non-enabled any claimto which that definition is applied. To the extent that any definitionor usage provided by any document incorporated herein by referenceconflicts with the definition or usage provided herein, the definitionor usage provided herein controls.

Regarding claim transitional terms or phrases, the transitional term“comprising,” which is synonymous with “including,” “containing,”“having,” or “characterized by,” is inclusive or open-ended and does notexclude additional, unrecited elements or method steps. The transitionalphrase “consisting of” excludes any element, step, or ingredient notspecified in the claim. The transitional phrase “consisting essentiallyof” limits the scope of a claim to the specified materials or steps andthose that do not materially affect the basic and novelcharacteristic(s) of the claim. A “consisting essentially of” claimoccupies a middle ground between closed claims that are written in a“consisting of” format and fully open claims that are drafted in a“comprising” format. Absent an indication to the contrary, describing acompound or composition as “consisting essentially of” is not to beconstrued as “comprising,” but is intended to describe the recitedcomponent that includes materials which do not significantly alter thecomposition or method to which the term is applied. For example, afeedstock consisting essentially of a material A can include impuritiestypically present in a commercially produced or commercially availablesample of the recited compound or composition. When a claim includesdifferent features and/or feature classes (for example, a method step,feedstock features, and/or product features, among other possibilities),the transitional terms comprising, consisting essentially of, andconsisting of apply only to the feature class to which it is utilized,and it is possible to have different transitional terms or phrasesutilized with different features within a claim. For example, a methodcan comprise several recited steps (and other non-recited steps), bututilize a system preparation consisting of specific components;alternatively, consisting essentially of specific components; oralternatively, comprising the specific components and other non-recitedcomponents.

While compositions and methods are often described in terms of“comprising” various components or steps, the compositions and methodscan also “consist essentially of” or “consist of” the various componentsor steps, unless stated otherwise.

The terms “a,” “an,” and “the” are intended to include pluralalternatives, e.g., at least one. For instance, the disclosure of “acatalyst deactivating agent,” “an olefin comonomer,” etc., is meant toencompass one, or mixtures or combinations of more than one, catalystdeactivating agent, olefin comonomer, etc., unless otherwise specified.

For any particular compound or group disclosed herein, any name orstructure (general or specific) presented is intended to encompass allconformational isomers, regioisomers, stereoisomers, and mixturesthereof that can arise from a particular set of substituents, unlessotherwise specified. The name or structure (general or specific) alsoencompasses all enantiomers, diastereomers, and other optical isomers(if there are any) whether in enantiomeric or racemic forms, as well asmixtures of stereoisomers, as would be recognized by a skilled artisan,unless otherwise specified. A general reference to pentane, for example,includes n-pentane, 2-methyl-butane, and 2,2-dimethylpropane; and ageneral reference to a butyl group includes a n-butyl group, a sec-butylgroup, an iso-butyl group, and a t-butyl group.

Within this disclosure, the normal rules of organic nomenclature willprevail. For instance, when referencing substituted compounds or groups,references to substitution patterns are taken to indicate that theindicated group(s) is(are) located at the indicated position and thatall other non-indicated positions are hydrogen. For example, referenceto a 4-substituted phenyl group indicates that there is a non-hydrogensubstituent located at the 4 position and hydrogens located at the 2, 3,5, and 6 positions. By way of another example, reference to a3-substituted naphth-2-yl indicates that there is a non-hydrogensubstituent located at the 3 position and hydrogens located at the 1, 4,5, 6, 7, and 8 positions. References to compounds or groups havingsubstitutions at positions in addition to the indicated position will bereferenced using comprising or some other alternative language. Forexample, a reference to a phenyl group comprising a substituent at the 4position refers to a phenyl group having a substituent at the 4 positionand hydrogen or any non-hydrogen substituent at the 2, 3, 5, and 6positions.

In one embodiment, a chemical “group” can be defined or describedaccording to how that group is formally derived from a reference or“parent” compound, for example, by the number of hydrogen atoms removedfrom the parent compound to generate the group, even if that group isnot literally synthesized in such a manner. These groups can be utilizedas substituents or coordinated or bonded to metal atoms. By way ofexample, an “alkyl group” formally can be derived by removing onehydrogen atom from an alkane, while an “alkylene group” formally can bederived by removing two hydrogen atoms from an alkane. Moreover, a moregeneral term can be used to encompass a variety of groups that formallyare derived by removing any number (“one or more”) hydrogen atoms from aparent compound, which in this example can be described as an “alkanegroup,” and which encompasses an “alkyl group,” an “alkylene group,” andmaterials having three or more hydrogen atoms, as necessary for thesituation, removed from an alkane. The disclosure that a substituent,ligand, or other chemical moiety can constitute a particular “group”implies that the well-known rules of chemical structure and bonding arefollowed when that group is employed as described. When describing agroup as being “derived by,” “derived from,” “formed by,” or “formedfrom,” such terms are used in a formal sense and are not intended toreflect any specific synthetic methods or procedures, unless specifiedotherwise or the context requires otherwise.

Also, unless otherwise specified, any carbon-containing group for whichthe number of carbon atoms is not specified can have, according toproper chemical practice, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14,15, 16, 17, or 18 carbon atoms, or any range or combination of rangesbetween these values. For example, unless otherwise specified, anycarbon-containing group can have from 1 to 18 carbon atoms, from 1 to 15carbon atoms, from 1 to 12 carbon atoms, from 1 to 10 carbon atoms, from1 to 8 carbon atoms, or from 1 to 5 carbon atoms, and the like.Moreover, other identifiers or qualifying terms can be utilized toindicate the presence of, or absence of, a particular substituent, aparticular regiochemistry, and/or stereochemistry, or the presence ofabsence of a branched underlying structure or backbone. Any specificcarbon-containing group is limited according to the chemical andstructural requirements for that specific group, as understood by one ofordinary skill. For example, unless otherwise specified, an aryl groupcan have from 6 to 18 carbon atoms, from 6 to 15 carbon atoms, from 6 to12 carbon atoms, or from 6 to 10 carbon atoms, and the like. Thus,according to proper chemical practice and unless otherwise specified, anaryl group can have 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18carbon atoms, or any range or combination of ranges between thesevalues.

Other numerical ranges are disclosed herein. When Applicants disclose orclaim a range of any type, Applicants' intent is to disclose or claimindividually each possible number that such a range could reasonablyencompass, including end points of the range as well as any sub-rangesand combinations of sub-ranges encompassed therein, unless otherwisespecified. As a representative example, Applicants disclose that aweight ratio of a catalyst deactivating agent to a transition metal in atransition metal-based catalyst system can be in a range from 1:1 to25:1 in certain embodiments. By a disclosure that the weight ratio ofthe catalyst deactivating agent to the transition metal in thetransition metal-based catalyst system can be in a range from 1:1 to25:1, Applicants intend to recite that the weight ratio can be equal to1:1, about 2:1, about 3:1, about 4:1, about 5:1, about 6:1, about 7:1,about 8:1, about 9:1, about 10:1, about 11:1, about 12:1, about 13:1,about 14:1, about 15:1, about 16:1, about 17:1, about 18:1, about 19:1,about 20:1, about 21:1, about 22:1, about 23:1, about 24:1, or 25:1.Additionally, the weight ratio can be within any range from 1:1 to 25:1(for example, the weight ratio can be in a range from about 2:1 to about10:1), and this also includes any combination of ranges between 1:1 and25:1. Likewise, all other ranges disclosed herein should be interpretedin a manner similar to these examples.

Applicants reserve the right to proviso out or exclude any individualmembers of any such group, including any sub-ranges or combinations ofsub-ranges within the group, that can be claimed according to a range orin any similar manner, if for any reason Applicants choose to claim lessthan the full measure of the disclosure, for example, to account for areference that Applicants can be unaware of at the time of the filing ofthe application. Further, Applicants reserve the right to proviso out orexclude any individual substituents, analogs, compounds, ligands,structures, or groups thereof, or any members of a claimed group, if forany reason Applicants choose to claim less than the full measure of thedisclosure, for example, to account for a reference that Applicants canbe unaware of at the time of the filing of the application.

The term “substituted” when used to describe a group or a chain ofcarbon atoms, for example, when referring to a substituted analog of aparticular group or chain, is intended to describe or group or chainwherein any non-hydrogen moiety formally replaces a hydrogen in thatgroup or chain, and is intended to be non-limiting. A group or chainalso can be referred to herein as “unsubstituted” or by equivalent termssuch as “non-substituted,” which refers to the original group or chain.“Substituted” is intended to be non-limiting and can include hydrocarbonsubstituents as specified and as understood by one of ordinary skill inthe art.

The term “hydrocarbon” whenever used in this specification and claimsrefers to a compound containing only carbon and hydrogen. Otheridentifiers can be utilized to indicate the presence of particulargroups in the hydrocarbon (e.g., halogenated hydrocarbon indicates thepresence of one or more halogen atoms replacing an equivalent number ofhydrogen atoms in the hydrocarbon). The term “hydrocarbyl group” is usedherein in accordance with the definition specified by IUPAC: a univalentgroup formed by removing a hydrogen atom from a hydrocarbon (that is, agroup containing only carbon and hydrogen). Similarly, a “hydrocarbylenegroup” refers to a group formed by removing two hydrogen atoms from ahydrocarbon, either two hydrogen atoms from one carbon atom or onehydrogen atom from each of two different carbon atoms. Therefore, inaccordance with the terminology used herein, a “hydrocarbon group”refers to a generalized group formed by removing one or more hydrogenatoms (as needed for the particular group) from a hydrocarbon. A“hydrocarbyl group,” “hydrocarbylene group,” and “hydrocarbon group” canbe acyclic or cyclic groups, and/or can be linear or branched. A“hydrocarbyl group,” “hydrocarbylene group,” and “hydrocarbon group” caninclude rings, ring systems, aromatic rings, and aromatic ring systems,which contain only carbon and hydrogen. “Hydrocarbyl groups,”“hydrocarbylene groups,” and “hydrocarbon groups” include, by way ofexample, aryl, arylene, arene groups, alkyl, alkylene, alkane groups,cycloalkyl, cycloalkylene, cycloalkane groups, aralkyl, aralkylene, andaralkane groups, respectively, among other groups as members.

An aliphatic compound is a non-aromatic organic compound. An “aliphaticgroup” is a generalized group formed by removing one or more hydrogenatoms (as needed for the particular group) from the carbon atoms of analiphatic compound. An aliphatic compound can be acyclic or cyclic,saturated or unsaturated, and/or linear or branched organic compound.Aliphatic compounds and aliphatic groups can contain organic functionalgroup(s) and/or atom(s) other than carbon and hydrogen unless otherwisespecified (e.g., an aliphatic hydrocarbon).

The term “alkane” whenever used in this specification and claims refersto a saturated hydrocarbon compound. Other identifiers can be utilizedto indicate the presence of particular groups in the alkane (e.g.,halogenated alkane indicates the presence of one or more halogen atomsreplacing an equivalent number of hydrogen atoms in the alkane). Theterm “alkyl group” is used herein in accordance with the definitionspecified by IUPAC: a univalent group formed by removing a hydrogen atomfrom an alkane. An “alkane group” is a general term that refers to agroup formed by removing one or more hydrogen atoms (as needed for theparticular group) from an alkane. An “alkyl group” and “alkane group”can be linear or branched unless otherwise specified. Primary,secondary, and tertiary alkyl groups can be derived by removal of ahydrogen atom from a primary, secondary, and tertiary carbon atom,respectively, of an alkane. The n-alkyl group can be derived by removalof a hydrogen atom from a terminal carbon atom of a linear alkane. Thegroups RCH₂ (R≠H), R₂CH(R≠H), and R₃C(R≠H) are primary, secondary, andtertiary alkyl groups, respectively. The carbon atom by which indicatedmoiety is attached is a secondary, tertiary, and quaternary carbon atom,respectively.

A cycloalkane is a saturated cyclic hydrocarbon, with or without sidechains (e.g., cyclobutane or methylcyclobutane). Unsaturated cyclichydrocarbons having at least one non-aromatic endocyclic carbon-carbondouble or one triple bond are cycloalkenes and cycloalkynes,respectively. Unsaturated cyclic hydrocarbons having more than one suchmultiple bond can further specify the number and/or position(s) of suchmultiple bonds (e.g., cycloalkadienes, cycloalkatrienes, and so forth).The unsaturated cyclic hydrocarbons can be further identified by theposition of the carbon-carbon multiple bond(s).

A “cycloalkyl group” is a univalent group derived by removing a hydrogenatom from a ring carbon atom from a cycloalkane. For example, a1-methylcyclopropyl group and a 2-methylcyclopropyl group areillustrated as follows:

A “cycloalkylene group” refers to a group derived by removing twohydrogen atoms from a cycloalkane, at least one of which is a ringcarbon. Thus, a “cycloalkylene group” includes a group derived from acycloalkane in which two hydrogen atoms are formally removed from thesame ring carbon, a group derived from a cycloalkane in which twohydrogen atoms are formally removed from two different ring carbons, anda group derived from a cycloalkane in which a first hydrogen atom isformally removed from a ring carbon and a second hydrogen atom isformally removed from a carbon atom that is not a ring carbon. A“cycloalkane group” refers to a generalized group formed by removing oneor more hydrogen atoms (as necessary for the particular group and atleast one of which is a ring carbon) from a cycloalkane.

The term “alkene” whenever used in this specification and claims refersto a compound that has at least one non-aromatic carbon-carbon doublebond. The term “alkene” includes aliphatic or aromatic, cyclic oracyclic, and/or linear and branched alkenes unless expressly statedotherwise. Alkenes can also be further identified by the position of thecarbon-carbon double bond. Alkenes having more than one such multiplebond are alkadienes, alkatrienes, and so forth. The alkene can befurther identified by the position(s) of the carbon-carbon doublebond(s).

An “alkenyl group” is a univalent group derived from an alkene byremoval of a hydrogen atom from any carbon atom of the alkene. Thus,“alkenyl group” includes groups in which the hydrogen atom is formallyremoved from an sp² hybridized (olefinic) carbon atom and groups inwhich the hydrogen atom is formally removed from any other carbon atom.For example and unless otherwise specified, propen-1-yl (—CH═CHCH₃),propen-2-yl [(CH₃)C═CH₂], and propen-3-yl (—CH₂CH═CH₂) groups are allencompassed with the term “alkenyl group.” Similarly, an “alkenylenegroup” refers to a group formed by formally removing two hydrogen atomsfrom an alkene, either two hydrogen atoms from one carbon atom or onehydrogen atom from two different carbon atoms. An “alkene group” refersto a generalized group formed by removing one or more hydrogen atoms (asneeded for the particular group) from an alkene. When the hydrogen atomis removed from a carbon atom participating in a carbon-carbon doublebond, the regiochemistry of the carbon from which the hydrogen atom isremoved, and regiochemistry of the carbon-carbon double bond can both bespecified. Alkenyl groups can also have more than one such multiplebond. The alkene group can also be further identified by the position(s)of the carbon-carbon double bond(s).

The term “alkyne” is used in this specification and claims to refer to acompound that has at least one carbon-carbon triple bond. The term“alkyne” includes aliphatic or aromatic, cyclic or acyclic, and/orlinear and branched alkynes unless expressly stated otherwise. Alkyneshaving more than one such multiple bond are alkadiynes, alkatriynes, andso forth. The alkyne group can also be further identified by theposition(s) of the carbon-carbon triple bond(s).

An “alkynyl group” is a univalent group derived from an alkyne byremoval of a hydrogen atom from any carbon atom of the alkyne. Thus,“alkynyl group” includes groups in which the hydrogen atom is formallyremoved from an sp hybridized (acetylenic) carbon atom and groups inwhich the hydrogen atom is formally removed from any other carbon atom.For example and unless otherwise specified, 1-propyn-1-yl (—C≡CCH₃) andpropyn-3-yl (HC≡CCH₂—) groups are encompassed with the term “alkynylgroup.” Similarly, an “alkynylene group” refers to a group formed byformally removing two hydrogen atoms from an alkyne, either two hydrogenatoms from one carbon atom if possible or one hydrogen atom from twodifferent carbon atoms. An “alkyne group” refers to a generalized groupformed by removing one or more hydrogen atoms (as needed for theparticular group) from an alkyne. Alkyne groups can have more than onesuch multiple bond. Alkyne groups can also be further identified by theposition(s) of the carbon-carbon triple bond(s).

An “aromatic group” refers to a generalized group formed by removing oneor more hydrogen atoms (as needed for the particular group and at leastone of which is an aromatic ring carbon atom) from an aromatic compound.Thus, an “aromatic group” as used herein refers to a group derived byremoving one or more hydrogen atoms from an aromatic compound, that is,a compound containing a cyclically conjugated hydrocarbon that followsthe Hückel (4n+2) rule and containing (4n+2) pi-electrons, where n is aninteger from 1 to about 5. Aromatic compounds and hence “aromaticgroups” can be monocyclic or polycyclic unless otherwise specified.Aromatic compounds include “arenes” (hydrocarbon aromatic compounds),examples of which can include, but are not limited to, benzene,naphthalene, and toluene, among others. As disclosed herein, the term“substituted” can be used to describe an aromatic group wherein anynon-hydrogen moiety formally replaces a hydrogen in that group, and isintended to be non-limiting.

An “aryl group” refers to a generalized group formed by removing ahydrogen atom from an aromatic hydrocarbon ring carbon atom from anarene. One example of an “aryl group” is ortho-tolyl (o-tolyl), thestructure of which is shown here.

Similarly, an “arylene group” refers to a group formed by removing twohydrogen atoms (at least one of which is from an aromatic hydrocarbonring carbon) from an arene. An “arene group” refers to a generalizedgroup formed by removing one or more hydrogen atoms (as needed for theparticular group and at least one of which is an aromatic hydrocarbonring carbon) from an arene.

An “aralkyl group” is an aryl-substituted alkyl group having a freevalance at a non-aromatic carbon atom, for example, a benzyl group is an“aralkyl” group. Similarly, an “aralkylene group” is an aryl-substitutedalkylene group having two free valances at a single non-aromatic carbonatom or a free valence at two non-aromatic carbon atoms while an“aralkane group” is a generalized is an aryl-substituted alkane grouphaving one or more free valances at a non-aromatic carbon atom(s).

The term “polymer” is used herein generically to include olefinhomopolymers, copolymers, terpolymers, and so forth. A copolymer can bederived from an olefin monomer and one olefin comonomer, while aterpolymer can be derived from an olefin monomer and two olefincomonomers. Accordingly, “polymer” encompasses copolymers, terpolymers,etc., derived from any olefin monomer and comonomer(s) disclosed herein.Similarly, an ethylene polymer would include ethylene homopolymers,ethylene copolymers, ethylene terpolymers, and the like. As an example,an olefin copolymer, such as an ethylene copolymer, can be derived fromethylene and a comonomer, such as 1-butene, 1-hexene, or 1-octene. Ifthe monomer and comonomer were ethylene and 1-hexene, respectively, theresulting polymer could be categorized an as ethylene/1-hexenecopolymer. The term “polymer” also is meant to include all molecularweight polymers, and is inclusive of lower molecular weight polymers oroligomers. Applicants intend for the term “polymer” to encompassoligomers derived from any olefin monomer disclosed herein (as well froman olefin monomer and one olefin comonomer, an olefin monomer and twoolefin comonomers, and so forth).

In like manner, the scope of the term “polymerization” includeshomopolymerization, copolymerization, terpolymerization, etc., as wellas processes that might also be referred to as oligomerizationprocesses. Therefore, a copolymerization process would involvecontacting an olefin monomer (e.g., ethylene) and an olefin comonomer(e.g., 1-hexene) to produce an olefin copolymer.

The terms “contact product,” “contacting,” and the like, are used hereinto describe compositions wherein the components are contacted togetherin any order, in any manner, and for any length of time. For example,the components can be contacted by blending or mixing. Further, unlessotherwise specified, the contacting of any component can occur in thepresence or absence of any other component of the compositions describedherein. Combining additional materials or components can be done by anysuitable method. Further, the term “contact product” includes mixtures,blends, solutions, slurries, reaction products, and the like, orcombinations thereof. Although “contact product” can, and often does,include reaction products, it is not required for the respectivecomponents to react with one another. Likewise, “contacting” two or morecomponents can result in a reaction product or a reaction mixture.Consequently, depending upon the circumstances, a “contact product” canbe a mixture, a reaction mixture, or a reaction product.

A “natural source oil” refers to an oil extracted, and optionallypurified, from a naturally occurring fruit, nut, vegetable, plant,and/or animal source. Representative and non-limiting examples of“natural source oils” include soybean oil and corn oil. “Natural sourceoil” also is meant to be inclusive of the respective oils extracted, andoptionally purified, from genetically modified fruit, nut, vegetable,plant, and/or animal sources, as well as enhanced derivatives orversions thereof. For instance, higher oleic acid versions of soybean,canola, and sunflower oils would still be considered soybean, canola,and sunflowers oils, respectively, within this disclosure and,therefore, are considered “natural source oils.” Often, these naturalsource oils may be referred to in the art as vegetable oils, cookingoils, edible oils, and the like.

Although any methods and materials similar or equivalent to thosedescribed herein can be used in the practice or testing of theinvention, the typical methods and materials are herein described.

All publications and patents mentioned herein are incorporated herein byreference for the purpose of describing and disclosing, for example, theconstructs and methodologies that are described in the publications,which might be used in connection with the presently describedinvention. The publications discussed throughout the text are providedsolely for their disclosure prior to the filing date of the presentapplication. Nothing herein is to be construed as an admission that theinventors are not entitled to antedate such disclosure by virtue ofprior invention.

DETAILED DESCRIPTION OF THE INVENTION

Disclosed herein are catalyst deactivating agents and methods forcontrolling a polymerization reaction in a polymerization reactor systemusing these catalyst deactivating agents. Compositions containing acatalyst deactivating agent also are provided.

Methods Utilizing a Catalyst Deactivating Agent

Methods of controlling a polymerization reaction in a polymerizationreactor system are disclosed. In an embodiment, a method of controllinga polymerization reaction in a polymerization reactor system can bedirected to partially or completely terminating the polymerizationreaction in a polymerization reactor within the polymerization reactorsystem, and/or to completely terminating the polymerization reactiondownstream of the polymerization reactor. In such instances, thepolymerization reaction can comprise contacting a transition metal-basedcatalyst system with an olefin monomer and optionally an olefincomonomer in the polymerization reactor under polymerization conditionsto produce an olefin polymer. The method of controlling thepolymerization reaction (e.g., a method of terminating thepolymerization reaction) can comprise introducing a catalystdeactivating agent into the polymerization reactor and/or downstream ofthe polymerization reactor.

Generally, the features of the methods disclosed herein (e.g., thetransition metal-based catalyst system, the olefin monomer, the catalystdeactivating agent, the polymerization reactor, among others) areindependently described herein, and these features can be combined inany combination to further describe the disclosed methods.

One method of controlling a polymerization reaction in a polymerizationreactor system consistent with embodiments disclosed herein cancomprise:

-   -   (i) introducing a transition metal-based catalyst system, an        olefin monomer, and optionally an olefin comonomer into a        polymerization reactor within the polymerization reactor system;    -   (ii) contacting the transition metal-based catalyst system with        the olefin monomer and the optional olefin comonomer under        polymerization conditions to produce an olefin polymer; and    -   (iii) introducing a catalyst deactivating agent into the        polymerization reactor to partially or completely terminate the        polymerization reaction in the polymerization reactor.

The catalyst deactivating agent can be introduced (e.g., added,injected, sprayed, etc.) into the polymerization reactor by any suitablemeans, either alone or with a carrier (e.g., a carrier gas, a carrierliquid, etc.). The polymerization reaction occurring within thepolymerization reactor system may be terminated for any of a number ofreasons. Illustrative examples can include, but are not limited to, anexcessive reactor temperature, a rapid increase in reactor temperature,an excessive reactor pressure, a rapid increase in reactor pressure, aloss of reactor coolant, a loss of gas flow in a fluidized bed reactor,an electrical failure in the reactor system, a mechanical failure in thereactor system, and an interruption in the operation of a piece ofequipment downstream of the reactor, among others. Additionally, anddepending upon the circumstances surrounding the reason for terminatingthe polymerization reaction, the termination of the polymerizationreaction can be accomplished either in a controlled manner or underrapid/emergency conditions. Additionally, and depending upon thecircumstances, it may be beneficial to partially terminate thepolymerization reaction (e.g., maintain some catalyst activity and/orsome polymer production rate), instead of completely terminating thepolymerization reaction.

Another method of controlling a polymerization reaction in apolymerization reactor system consistent with embodiments disclosedherein can comprise:

-   -   (1) introducing a transition metal-based catalyst system, an        olefin monomer, and optionally an olefin comonomer into a        polymerization reactor within the polymerization reactor system;    -   (2) contacting the transition metal-based catalyst system with        the olefin monomer and the optional olefin comonomer under        polymerization conditions to produce an olefin polymer; and    -   (3) introducing a catalyst deactivating agent into the        polymerization reactor system downstream of the polymerization        reactor to completely terminate the polymerization reaction.

The catalyst deactivating agent can be introduced (e.g., added,injected, sprayed, etc.) downstream of the polymerization reactor by anysuitable means, either alone or with a carrier (e.g., a carrier gas, acarrier liquid, etc.). Typically, the polymerization reaction can beterminated in an outlet pipe, in a discharge pipe, etc., or in anothermeans of conveyance, from the polymerization reactor. Often, thecatalyst deactivating agent can be added prior to a separations deviceor apparatus. The addition of a catalyst deactivating agent downstreamof the reactor can neutralize any remaining active catalyst in theolefin polymer, and prevent any further reaction with olefin monomerand/or comonomer. Moreover, the addition of the catalyst deactivatingagent downstream of the reactor can be substantially continuous andoptionally at a fixed ratio based upon the polymer production or outputrate. Using the disclosed catalyst deactivating agents to terminate thepolymerization reaction and neutralize residual catalyst at this stagein the polymerization reactor system can, for instance, reduce skinformation in downstream equipment, prevent interactions with additivessuch as antioxidants, and reduce off-color formation in the polymer. Inaddition, certain catalyst deactivating agents disclosed herein canremain with the olefin polymer, if desired, and do not have to beevaporated/separated from the polymer, recycled, dried, etc. Forinstance, in certain embodiments, the catalyst deactivating agentbeneficially can be non-toxic and/or can be permissible for use in foodpackaging applications. Moreover, it is also contemplated that thepresence of certain disclosed catalyst deactivating agents in the finalpolymer may improve the frictional or slip properties of the polymerproduced.

Yet another method of controlling a polymerization reaction in apolymerization reactor system consistent with embodiments disclosedherein can comprise:

-   -   (a) introducing a transition metal-based catalyst system, an        olefin monomer, and optionally an olefin comonomer into a        polymerization reactor within the polymerization reactor system;    -   (b) contacting the transition metal-based catalyst system with        the olefin monomer and the optional olefin comonomer under        polymerization conditions to produce an olefin polymer;    -   (c) monitoring a process variable to detect an undesired        condition in the polymerization reactor system; and    -   (d) when the undesired reaction condition has reached a        predetermined critical level, introducing a catalyst        deactivating agent into the polymerization reactor.

Many process variables can be monitored during the operation of apolymerization reactor in a polymerization reactor system. These caninclude, but are not limited to, reactor temperature, reactor pressure,catalyst system flow rate into the reactor, monomer flow rate (andcomonomer, if employed) into the reactor, olefin polymer output rate,recycle rate, hydrogen flow rate (if employed), reactor cooling status,circulation pump power, and the like. Process variables can be monitoredto detect an undesired condition in the polymerization reactor system.As a non-limiting example, the reactor temperature can be monitored toensure that the temperature within the reactor does not increase to anundesired temperature, or that the rate of increase of the temperaturewithin the reactor does not exceed an undesired level. As anotherexample, the undesired condition can be a partial or complete loss ofreactor cooling in the system. When the undesired condition has reacheda predetermined critical level (e.g., a temperature which is too high, arate of increase in temperature which is too rapid, a complete loss ofreactor cooling, etc.), the catalyst deactivating agent can beintroduced into the polymerization reactor. As part of the operation ofthe polymerization reactor system, it can be pre-determined that,depending upon the nature of the undesired condition, the deactivatingagent can be introduced within 30 minutes, within 15 minutes, within 10minutes, within 5 minutes, within 1 minute, or within 30 seconds, afterthe undesired condition reaches the predetermined critical level. It isalso contemplated that the deactivating agent can be added to thepolymerization reactor instantaneously upon determining that theundesired condition has reached the predetermined critical level.

In the methods of controlling a polymerization reaction in apolymerization reactor system described herein, Applicants alsocontemplate that these methods can further comprise a step ofdiscontinuing the introducing of the transition metal-based catalystsystem into the polymerization reactor within the polymerization reactorsystem. The step of discontinuing the introducing of the transitionmetal-based catalyst system into the polymerization reactor can occurbefore, during, or after the step of introducing the catalystdeactivating agent into the polymerization reactor. For example, in someembodiments, it can be beneficial to discontinue the introducing of thetransition metal-based catalyst system into the polymerization reactorconcurrently with the step of introducing the catalyst deactivatingagent into the polymerization reactor. Moreover, these methods canfurther comprise a step of restarting polymerization in thepolymerization reactor by re-introducing the transition metal-basedcatalyst into the polymerization reactor. Depending upon thecircumstances related to the reason for adding the catalyst deactivatingagent (e.g., an emergency shutdown, a planned long term outage, a shortoutage, etc.), polymerization often can be restarted within from 5-15minutes to 36-48 hours after the step of introducing the catalystdeactivating agent into the polymerization reactor. Polymerization canbe restarted, in some embodiments, within 12 hours, within 8 hours,within 6 hours, within 2 hours, or within 1 hour, after the step ofintroducing the catalyst deactivating agent into the polymerizationreactor.

Likewise, in the methods disclosed herein, Applicants contemplate thatthese methods can further comprise a step of discontinuing theintroducing of the olefin monomer into the polymerization reactor. Thisstep can occur before, during, or after the step of introducing thecatalyst deactivating agent into the polymerization reactor. As with thediscontinuing the introducing of the transition metal-based catalystsystem, it can be beneficial in some embodiments to discontinue theintroducing of the olefin monomer into the polymerization reactorconcurrently with the step of introducing the catalyst deactivatingagent into the polymerization reactor. Additionally, these methods canfurther comprise a step of restarting polymerization in thepolymerization reactor by re-introducing the olefin monomer into thepolymerization reactor. As above, depending upon the circumstancesrelated to the reason for adding the catalyst deactivating agent,polymerization often can be restarted within from 10 minutes to 36hours, for example, after the step of introducing the catalystdeactivating agent into the polymerization reactor. In an embodiment,polymerization can be restarted within 12 hours, within 8 hours, within6 hours, within 2 hours, or within 1 hour, after the step of introducingthe catalyst deactivating agent into the polymerization reactor.

In the methods disclosed herein, a step can comprise introducing atransition metal-based catalyst system, an olefin monomer, andoptionally an olefin comonomer into the polymerization reactor. As wouldbe recognized by one of skill in the art, additional components can beintroduced into the polymerization reactor in addition to the transitionmetal-based catalyst system and the olefin monomer (and, olefincomonomer(s), if desired), and such unrecited components are encompassedherein. For instance, in the operation of a polymerization reactorsystem—depending, of course, on the polymerization reactor type, thedesired olefin polymer, etc., among other factors—solvents and/ordiluents and/or fluidizing gases, recycle streams, hydrogen, etc., alsocan be added or introduced into the polymerization reactor andpolymerization reactor system.

While the methods disclosed herein can further comprise a step ofdiscontinuing the introducing of the olefin monomer and/or thetransition metal-based catalyst system into the polymerization reactor,other process steps can be conducted before, during, or after the stepof introducing the catalyst deactivating agent into the polymerizationreactor or reactor system. For example, reactor vents can be openedbefore, during, or after the step of introducing the catalystdeactivating agent into the polymerization reactor or reactor system.The flow of a reactor recycle stream can be discontinued before, during,or after the step of introducing the catalyst deactivating agent intothe polymerization reactor or reactor system. However, in someembodiments, it can be advantageous to continue the flow of the reactorrecycle stream after the step of introducing the catalyst deactivatingagent into the polymerization reactor to improve the distribution of thecatalyst deactivating agent throughout the polymerization reactorsystem. It is also contemplated that only the non-recycled olefinmonomer flow can be discontinued before, during, or after the step ofintroducing the catalyst deactivating agent into the polymerizationreactor.

In another method of controlling a polymerization reaction in apolymerization reactor system consistent with embodiments disclosedherein, the method can comprise:

-   -   (A) introducing a first transition metal-based catalyst system,        a first olefin monomer, and optionally a first olefin comonomer        into a polymerization reactor in the polymerization reactor        system;    -   (B) contacting the first transition metal-based catalyst system        with the first olefin monomer and the optional first olefin        comonomer under polymerization conditions to produce a first        olefin polymer;    -   (C) discontinuing the introducing of the first transition        metal-based catalyst system into the polymerization reactor        before, during, or after a step of introducing a catalyst        deactivating agent into the polymerization reactor; and    -   (D) introducing a second transition metal-based catalyst system        into the polymerization reactor and contacting the second        transition metal-based catalyst system with a second olefin        monomer and optionally a second olefin comonomer under        polymerization conditions to produce a second olefin polymer.

This method of controlling a polymerization reaction in a polymerizationreactor system can be directed to a method of transitioning from a firsttransition metal-based catalyst system to a second transitionmetal-based catalyst system in a polymerization reactor within thepolymerization reactor system. In this method of controlling apolymerization reaction in a polymerization reactor system (e.g.,transitioning from a first transition metal-based catalyst system to asecond transition metal-based catalyst system), Applicants contemplatethat the first transition metal-based catalyst system and the secondtransition metal-based catalyst system can be different catalyst systems(e.g., transitioning from a Ziegler-Natta based catalyst system to ametallocene-based catalyst system) or can be different catalyst systemsof the same type (e.g., transitioning from a first metallocene-basedcatalyst system to a second metallocene-based catalyst system,transitioning from a first chromium-based catalyst system to a secondchromium-based catalyst system, etc.). Additionally or alternatively,the first olefin polymer and the second olefin polymer can be different(e.g., transitioning from an ethylene homopolymer to an ethylenecopolymer) or can be different grades of the same polymer type (e.g.,transitioning from a first ethylene copolymer having a first melt indexand a first density to a second ethylene copolymer having a second meltindex and a second density). Likewise, the first olefin monomer and thesecond olefin monomer can be the same or different, and the first olefincomonomer (if used) and the second olefin comonomer (if used) can be thesame or different. For instance, the first olefin monomer and the secondolefin monomer can be the same, but no comonomer is used; alternatively,the first olefin monomer and the second olefin monomer can be different,but no comonomer is used; alternatively, the first olefin monomer andthe second olefin monomer can be the same, and the first olefincomonomer and the second olefin comonomer can be the same or different;or alternatively, the first olefin monomer and the second olefin monomercan be the same, but no first olefin comonomer is used, and a secondolefin comonomer is used. In circumstances where the second olefinmonomer is different from the first olefin monomer and/or where thesecond olefin comonomer is different from the first olefin comonomer,the disclosed methods can further comprise a step of discontinuing theintroducing of the first olefin monomer (and, if needed, discontinuingthe introducing of the first olefin comonomer) into the polymerizationreactor. This step can occur before, during, or after the step ofintroducing the catalyst deactivating agent into the polymerizationreactor.

In each of the methods of controlling a polymerization reaction in apolymerization reactor system disclosed and described herein, the stepof introducing the catalyst deactivating agent into the polymerizationreactor (or into the polymerization reactor system downstream of thepolymerization reactor) can reduce the catalyst activity of thetransition metal-based catalyst system and/or can reduce the productionrate of the olefin polymer by at least 50%. Applicants contemplate thatthere can be instances where the catalyst activity and/or productionrate may need to be decreased by 50% or more (e.g., a partial kill wherethe reaction is not terminated, merely slowed down), as well asinstances where a substantially complete or total termination of thepolymerization reaction (95-100% decrease) may be needed. Hence, thereare instances where the step of introducing the catalyst deactivatingagent into the polymerization reactor (or into the polymerizationreactor system downstream of the polymerization reactor) can reduce thecatalyst activity of the transition metal-catalyst system and/or canreduce the production rate of the olefin polymer by at least 50%, whilethere are other instances where the step of introducing the catalystdeactivating agent into the polymerization reactor can reduce thecatalyst activity of the transition metal-catalyst system and/or canreduce the production rate of the olefin polymer by at least 60%, by atleast 70%, or by at least 80%. Furthermore, in certain embodiments, thestep of introducing the catalyst deactivating agent into thepolymerization reactor (or into the polymerization reactor systemdownstream of the polymerization reactor) can reduce the catalystactivity of the transition metal-catalyst system and/or can reduce theproduction rate of the olefin polymer by at least 85%; alternatively, byat least 90%; alternatively, by at least 95%; alternatively, by at least98%; alternatively, by at least 99%, or alternatively, by 100%.

The step of introducing the catalyst deactivating agent into thepolymerization reactor (or into the polymerization reactor systemdownstream of the polymerization reactor) can substantially reduce thecatalyst activity of the transition metal-catalyst system and/orsubstantially reduce the production rate of the olefin polymer over awide range of time periods, depending upon the desired circumstances,for example, in time periods ranging from as little as 1-30 seconds toas long as 1-2 hours. Often, however, the reduction in catalyst activityand/or production rate can be accomplished relatively rapidly. Forinstance, the step of introducing the catalyst deactivating agent intothe polymerization reactor or reactor system can reduce the catalystactivity of the transition metal-catalyst system and/or can reduce theproduction rate of the olefin polymer by from 50% to 100% in a timeperiod of less than 30 minutes, less than 15 minutes, less than 10minutes, or less than 5 minutes, or less than one minute. In someembodiments, the step of introducing the catalyst deactivating agentinto the polymerization reactor or reactor system can reduce thecatalyst activity of the transition metal-catalyst system and/or reducethe production rate of the olefin polymer by at least 50%, by least 75%,by at least 85%, or by from 95-100%, in a time period of less than 5minutes, less than 4 minutes, less than 3 minutes, or less than 2minutes. In other embodiments, the catalyst activity of the transitionmetal-catalyst system and/or production rate of the olefin polymer canbe reduced even more rapidly, such as, for example, a reduction of atleast 50%, at least 75%, at least 85%, or by from 95-100%, etc., in lessthan 1 minute, in less than 45 seconds, or in less than 30 seconds.Further, the catalyst activity of the transition metal-catalyst systemand/or production rate of the olefin polymer can be reduced by 95-100%,and this can occur instantaneously or substantially instantaneously. Asone of skill in the art would recognize, the time period for reducingthe catalyst activity and/or production rate can depend upon, forexample, mass transfer limitations and/or residence time considerationswithin the polymerization reactor and polymerization reactor system.

In each of the methods of controlling a polymerization reaction in apolymerization reactor system disclosed and described herein, thecatalyst deactivating agent can be introduced—into the polymerizationreactor or into the polymerization reactor system downstream of thepolymerization reactor—at a weight ratio of the catalyst deactivatingagent to the transition metal in the transition metal-based catalystsystem in a range from 0.001:1 to 1000:1, from 0.01:1 to 1000:1, from0.01:1 to 500:1, from 0.1:1 to 1000:1, or from 0.1:1 to 500:1. Theamount of catalyst deactivating agent employed can vary depending on,for example, the type of transition metal-based catalyst system, whethera co-catalyst is used, whether a partial or complete termination of thepolymerization reaction is desired, the desired time period or rapidnessfor terminating the polymerization reaction, whether the polymerizationreaction will be re-started shortly after termination, etc., among otherfactors. Suitable ranges for the weight ratio of the amount of thecatalyst deactivating agent added to the reactor or reactor system basedon the amount of the transition metal in the transition metal-basedcatalyst system present in the reactor or reactor system at the time ofaddition can include, but are not limited to, from 0.1:1 to 400:1, from0.1:1 to 250:1, from 0.1:1 to 100:1, from 1:1 to 100:1, from 0.5:1 to250:1, from 0.5:1 to 100:1, from 0.5:1 to 50:1, from 1:1 to 50:1, orfrom 1:1 to 25:1, and the like.

The catalyst deactivating agent can be introduced into thepolymerization reactor, or into the polymerization reactor systemdownstream of the polymerization reactor, without a carrier or diluent.Alternatively, the catalyst deactivating agent can be introduced intothe polymerization reactor, or into the polymerization reactor systemdownstream of the polymerization reactor, in the form of a mixture,suspension, solution, etc., along with a hydrocarbon solvent. Forinstance, the catalyst deactivating agent can be suspended or dissolvedin a hydrocarbon solvent(s), and the catalyst deactivating agent and therespective hydrocarbon solvent(s) can be introduced together into thepolymerization reactor or reactor system. Exemplary hydrocarbon solventscan comprise (or consist essentially of, or consist of) a C₃ to C₁₀hydrocarbon; alternatively, a C₃ to C₁₀ aliphatic hydrocarbon;alternatively, a C₃ to C₈ aliphatic hydrocarbon; or alternatively, a C₄to C₈ aliphatic hydrocarbon. The aliphatic hydrocarbon can be cyclic oracyclic and/or can be linear or branched, unless otherwise specified.Illustrative aliphatic hydrocarbon solvents can include, but are notlimited to, propane, isobutane, n-butane, n-pentane, isopentane,neopentane, n-hexane, heptane, octane, cyclohexane, cycloheptane,methylcyclohexane, methylcycloheptane, and the like, including mixturesor combinations thereof.

Moreover, the hydrocarbon solvent can comprise (or consist essentiallyof, or consist of) a C₆ to C₁₀ aromatic hydrocarbon or, alternatively, aC₆ to C₈ aromatic hydrocarbon. Illustrative aromatic hydrocarbonsolvents can include, but are not limited to, benzene, toluene, xylene,ethylbenzene, and the like, including mixtures or combinations thereof.

In an embodiment, the catalyst deactivating agent can be suspended ordissolved in a hydrocarbon solvent, and the hydrocarbon solvent cancomprise (or consist essentially of, or consist of) propane, isobutane,n-butane, n-pentane, isopentane, neopentane, n-hexane, heptane, octane,cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane,benzene, toluene, xylene, ethylbenzene, and the like, or a mixturethereof. In another embodiment, the hydrocarbon solvent can comprisepropane, cyclohexane, isobutane, n-butane, n-pentane, isopentane,neopentane, n-hexane, or a mixture thereof. In yet another embodiment,the hydrocarbon solvent can comprise propane; alternatively, isobutane;alternatively, n-butane; alternatively, n-pentane; alternatively,isopentane; alternatively, neopentane; alternatively, n-hexane;alternatively, heptane; alternatively, octane; alternatively,cyclohexane; alternatively, cycloheptane; alternatively,methylcyclohexane; alternatively, methylcycloheptane; alternatively,benzene; alternatively, toluene; alternatively, xylene; oralternatively, ethylbenzene. In still another embodiment, thehydrocarbon solvent can comprise an ISOPAR® mixed aliphatic hydrocarbonsolvent, such as, for example, ISOPAR® C, ISOPAR® E, ISOPAR® G, ISOPAR®H, ISOPAR® L, ISOPAR® M, or a mixture thereof.

In the above methods, the step of introducing the catalyst deactivatingagent into the polymerization reactor, or into the polymerizationreactor system downstream of the polymerization reactor, cansubstantially reduce the catalyst activity of the transitionmetal-catalyst system and/or substantially reduce the production rate ofthe olefin polymer. Catalyst activity can be measured, for example, inunits of grams of olefin polymer (ethylene homopolymer, ethylenecopolymer, propylene homopolymer, etc., as the context requires) pergram of transition metal per hour (g/g-TM/hr), or in units of grams ofolefin polymer per mole of transition metal per hour (g/mol-TM/hr). Theproduction rate of the olefin polymer or the polymer output rate can bemeasured, for example, in the same units as that of catalyst activity,or in units of pounds of olefin polymer produced per hour (lb/hr). Inembodiments directed to continuous polymerization reactor systems (e.g.,slurry, gas phase, solution, and the like), the impact of the step ofintroducing the catalyst deactivating agent into the polymerizationreactor or reactor system on the production rate of the olefin polymermay be easier to quantify than the impact on the catalyst activity.

Catalyst Deactivating Agents

Consistent with certain embodiments disclosed herein, the catalystdeactivating agent can comprise a natural source oil. Suitable naturalsource oils can include, but are not limited to, a tallow oil, an oliveoil, a peanut oil, a castor bean oil, a sunflower oil, a sesame oil, apoppy seed oil, a palm oil, an almond seed oil, a hazelnut oil, arapeseed oil, a canola oil, a soybean oil, a corn oil, a safflower oil,a cottonseed oil, a camelina oil, a flaxseed oil, a walnut oil, and thelike, as well as any mixture of combination thereof. In one embodiment,the catalyst deactivating agent can comprise a natural source oil, andthe natural source oil is or can comprise a tallow oil; alternatively,an olive oil; alternatively, a peanut oil; alternatively, a castor beanoil; alternatively, a sunflower oil; alternatively, a sesame oil;alternatively, a poppy seed oil; alternatively, a palm oil;alternatively, an almond seed oil; alternatively, a hazelnut oil;alternatively, a rapeseed oil; alternatively, a canola oil;alternatively, a soybean oil; alternatively, a corn oil; alternatively,a safflower oil; alternatively, a cottonseed oil; alternatively, acamelina oil; alternatively, a flaxseed oil; or alternatively, a walnutoil. In another embodiment, the catalyst deactivating agent can comprisea natural source oil, and the natural source oil can comprise a soybeanoil, a corn oil, a canola oil, a castor bean oil, or a combinationthereof. In yet another embodiment, the catalyst deactivating agent cancomprise a natural source oil, and the natural source oil is or cancomprise a corn oil.

Consistent with certain embodiments disclosed herein, the catalystdeactivating agent can comprise a siloxane. As a non-limiting example,for instance, the catalyst deactivating agent can comprise a siloxane,and the siloxane can have the following formula:

Generally, the selections of R and n in formula (I) are independentlydescribed herein, and these selections can be combined in anycombination to further describe the siloxane catalyst deactivating agenthaving formula (I).

In an embodiment, each R independently can be a C₁ to C₁₈ hydrocarbylgroup; alternatively, a C₁ to C₁₂ hydrocarbyl group; alternatively, a C₁to C₁₀ hydrocarbyl group; alternatively, a C₁ to C₈ hydrocarbyl group;or alternatively, a C₁ to C₅ hydrocarbyl group. In another embodiment,each R independently can be a C₁ to C₁₈ alkyl group, a C₂ to C₁₈ alkenylgroup, a C₆ to C₁₈ aryl group, or a C₇ to C₁₈ aralkyl group. Forinstance, each R independently can be a C₁ to C₁₂ alkyl group, a C₂ toC₁₂ alkenyl group, a C₆ to C₁₅ aryl group, or a C₇ to C₁₅ aralkyl group;alternatively, each R independently can be a C₁ to C₁₀ alkyl group, a C₂to C₁₀ alkenyl group, a C₆ to C₁₂ aryl group, or a C₇ to C₁₂ aralkylgroup; alternatively, each R independently can a C₁ to C₈ alkyl group, aC₂ to C₈ alkenyl group, a C₆ to C₁₀ aryl group, or a C₇ to C₁₀ aralkylgroup; or alternatively, each R independently can be a C₁ to C₅ alkylgroup, a C₂ to C₅ alkenyl group, a C₆ to C₈ aryl group, or a C₇ to C₈aralkyl group. It is contemplated in these and other embodiments thateach R can be the same, or that each R can be different.

Accordingly, in some embodiments, the alkyl group which can be R,independently, in formula (I) can be a methyl group, an ethyl group, apropyl group, a butyl group, a pentyl group, a hexyl group, a heptylgroup, an octyl group, a nonyl group, a decyl group, a undecyl group, adodecyl group, a tridecyl group, a tetradecyl group, a pentadecyl group,a hexadecyl group, a heptadecyl group, or an octadecyl group; oralternatively, a methyl group, an ethyl group, a propyl group, a butylgroup, a pentyl group, a hexyl group, a heptyl group, an octyl group, anonyl group, or a decyl group. In other embodiments, the alkyl groupwhich can be R, independently, in formula (I) can be a methyl group, anethyl group, a n-propyl group, an iso-propyl group, a n-butyl group, aniso-butyl group, a sec-butyl group, a tert-butyl group, a n-pentylgroup, an iso-pentyl group, a sec-pentyl group, or a neopentyl group;alternatively, a methyl group, an ethyl group, an iso-propyl group, an-butyl group, a tert-butyl group, or a neopentyl group; alternatively,a methyl group; alternatively, an ethyl group; alternatively, a n-propylgroup; alternatively, an iso-propyl group; alternatively, a n-butylgroup; alternatively, a tert-butyl group; or alternatively, a neopentylgroup.

Illustrative alkenyl groups which can be R, independently, in formula(I) can include, but are not limited to, an ethenyl group, a propenylgroup, a butenyl group, a pentenyl group, a hexenyl group, a heptenylgroup, an octenyl group, a nonenyl group, a decenyl group, a undecenylgroup, a dodecenyl group, a tridecenyl group, a tetradecenyl group, apentadecenyl group, a hexadecenyl group, a heptadecenyl group, or anoctadecenyl group. In one embodiment, each R in formula (I)independently can be an ethenyl group, a propenyl group, a butenylgroup, a pentenyl group, a hexenyl group, a heptenyl group, an octenylgroup, a nonenyl group, or a decenyl group, while in another embodiment,each R in formula (I) independently can be an ethenyl group, a propenylgroup, a butenyl group, a pentenyl group, or a hexenyl group. Forexample, each R can be an ethenyl group; alternatively, a propenylgroup; alternatively, a butenyl group; alternatively, a pentenyl group;or alternatively, a hexenyl group. In yet another embodiment, each Rindependently can be an acyclic terminal alkenyl group, such as a C₃ toC₁₀, or a C₃ to C₈, terminal alkenyl group.

In some embodiments, the aryl group which can be R, independently, informula (I) can be a phenyl group, a substituted phenyl group, anaphthyl group, or a substituted naphthyl group. In an embodiment, thearyl group can be a phenyl group or a substituted phenyl group;alternatively, a naphthyl group or a substituted naphthyl group;alternatively, a phenyl group or a naphthyl group; or alternatively, asubstituted phenyl group or a substituted naphthyl group. Substituentswhich can be utilized for the substituted phenyl group or substitutednaphthyl group are independently disclosed herein and can be utilizedwithout limitation to further describe the substituted phenyl group orsubstituted naphthyl group which can be utilized as R in formula (I).

In an embodiment, the substituted phenyl group which can be utilized asR, independently, can be a 2-substituted phenyl group, a 3-substitutedphenyl group, a 4-substituted phenyl group, a 2,4-disubstituted phenylgroup, a 2,6-disubstituted phenyl group, 3,5-disubstituted phenyl group,or a 2,4,6-trisubstituted phenyl group. In other embodiments, thesubstituted phenyl group can be a 2-substituted phenyl group, a4-substituted phenyl group, a 2,4-disubstituted phenyl group, or a2,6-disubstituted phenyl group; alternatively, a 3-substituted phenylgroup or a 3,5-disubstituted phenyl group; alternatively, a2-substituted phenyl group or a 4-substituted phenyl group;alternatively, a 2,4-disubstituted phenyl group or a 2,6-disubstitutedphenyl group; alternatively, a 2-substituted phenyl group;alternatively, a 3-substituted phenyl group; alternatively, a4-substituted phenyl group; alternatively, a 2,4-disubstituted phenylgroup; alternatively, a 2,6-disubstituted phenyl group; alternatively,3,5-disubstituted phenyl group; or alternatively, a 2,4,6-trisubstitutedphenyl group. Substituents which can be utilized for these specificsubstituted phenyl groups are independently disclosed herein and can beutilized without limitation to further describe these substituted phenylgroups which can be utilized as the R group of formula (I).

In some embodiments, the aralkyl group which can be utilized as R informula (I), independently, can be a benzyl group or a substitutedbenzyl group. Substituents which can be utilized for the substitutedaralkyl group are independently disclosed herein and can be utilizedwithout limitation to further describe the substituted aralkyl groupwhich can be utilized as R in formula (I).

In an embodiment, each non-hydrogen substituent for the substituted arylgroup or substituted aralkyl group which can be R in formula (I)independently can be a C₁ to C₁₀ hydrocarbyl group; alternatively, a C₁to C₈ hydrocarbyl group; or alternatively, a C₁ to C₅ hydrocarbyl group.Specific substituent hydrocarbyl groups are independently disclosedherein and can be utilized without limitation to further describe thesubstituents of the substituted aryl group or substituted aralkyl groupwhich can be R in formula (I). The number of substituents and theirrespective number of carbon atoms in any substituted aryl group orsubstituted aralkyl group is limited such that each R in formula (I)generally can have up to about 18 carbon atoms. Exemplary hydrocarbylsubstituents can include, but are not limited to, an alkyl group, suchas a methyl group, an ethyl group, a n-propyl group, an isopropyl group,a n-butyl group, a sec-butyl group, an isobutyl group, a tert-butylgroup, a n-pentyl group, a 2-pentyl group, a 3-pentyl group, a2-methyl-1-butyl group, a tert-pentyl group, a 3-methyl-1-butyl group, a3-methyl-2-butyl group, or a neo-pentyl group, and the like, includingcombinations thereof.

In one embodiment, each R independently can be a C₁ to C₁₂ alkyl group,a C₂ to C₁₂ alkenyl group, a C₆ to C₁₅ aryl group, or a C₇ to C₁₅aralkyl group; or alternatively, a C₁ to C₁₂ alkyl group, a C₂ to C₁₂alkenyl group, a C₆ to C₁₅ aryl group, or a C₇ to C₁₅ aralkyl group. Inanother embodiment, each R independently can be a C₁ to C₁₂ alkyl group.In yet another embodiment, each R independently can be methyl, ethyl,propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, phenyl,benzyl, or tolyl; alternatively, methyl, ethyl, propyl, butyl, pentyl,hexyl, heptyl, octyl, phenyl, benzyl, or tolyl; alternatively, methyl,ethyl, propyl, butyl, pentyl, hexyl, phenyl, benzyl, or tolyl; oralternatively, methyl, ethyl, propyl, butyl, or pentyl. In still anotherembodiment, each R can be the same and can be methyl, ethyl, propyl,butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, phenyl, benzyl, ortolyl; alternatively, methyl, ethyl, propyl, butyl, pentyl, hexyl,heptyl, octyl, phenyl, benzyl, or tolyl; alternatively, methyl, ethyl,propyl, butyl, phenyl, or benzyl; alternatively, methyl, ethyl, propyl,or butyl; or alternatively, methyl.

The integer n in formula (I) can be greater than or equal to 2. In oneembodiment, n can be an integer in a range from 2 to 900, or from 3 to800, while in another embodiment, n can be an integer in a range from 3to 500, or from 5 to 250.

The catalyst deactivating agent can comprise a siloxane, and in someembodiments, the siloxane can comprise hexamethyldisiloxane,octamethyltrisiloxane, tetramethyltetraphenyltrisiloxane,trimethylpentaphenyltrisiloxane, decamethyltetrasiloxane,octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane,dodecamethylpentasiloxane, dodecamethylcyclohexasiloxane, adimethyl-diphenylsiloxane, a phenylmethylsiloxane-dimethylsiloxane, aphenylmethylsiloxane, a polydimethylsiloxane, and the like, or anymixture or combination thereof. For example, the catalyst deactivatingagent can comprise hexamethyldisiloxane; alternatively,octamethyltrisiloxane; alternatively, tetramethyltetraphenyltrisiloxane;alternatively, trimethylpentaphenyltrisiloxane; alternatively,decamethyltetrasiloxane; alternatively, octamethylcyclotetrasiloxane;alternatively, decamethylcyclopentasiloxane; alternatively,dodecamethylpentasiloxane; alternatively, dodecamethylcyclohexasiloxane;alternatively, a dimethyl-diphenylsiloxane; alternatively, aphenylmethylsiloxane-dimethylsiloxane; alternatively, aphenylmethylsiloxane; or alternatively, a polydimethylsiloxane.

Suitable siloxanes useful as catalyst deactivating agents can have abroad range of viscosities, typically less than 10,000 cSt at 25° C., orin a range from 1 to about 10,000 cSt at 25° C. In some embodiments, thesiloxane can have a viscosity at 25° C. in a range from 2 to 5,000 cSt,from 2 to 2,500 cSt, from 2 to 1,000 cSt, or from 2 to 500 cSt. Yet, inother embodiments, the siloxane can have a viscosity at 25° C. in arange from 5 to 1,000 cSt, from 10 to 1,000 cSt, from 10 to 500 cSt, orfrom 20 to 350 cSt.

In accordance with an embodiment disclosed herein, the catalystdeactivating agent can have, beneficially, a boiling point of at least80° C. at atmospheric pressure, such as, for example, a boiling point ofat least 100° C., a boiling point of at least 120° C., or a boilingpoint of at least 150° C. Catalyst deactivating agents having boilingpoints of at least 175° C., or at least 200° C., can be employed aswell. Yet, in another embodiment, the catalyst deactivating agent canhave a boiling point in the 70° C. to 500° C. range; alternatively, aboiling point in the 80° C. to 450° C. range; alternatively, a boilingpoint in the 100° C. to 300° C. range; alternatively, a boiling point inthe 120° C. to 375° C. range; alternatively, a boiling point in the 100°C. to 250° C. range; alternatively, a boiling point in the 100° C. to350° C. range; alternatively, a boiling point in the 175° C. to 400° C.range; alternatively, a boiling point in the 175° C. to 300° C. range;or alternatively, a boiling point in the 150° C. to 450° C. range.

In another embodiment, it can be beneficial for the catalystdeactivating agent to remain in the liquid phase over a wide range oftemperatures. For example, the catalyst deactivating agent can be aliquid throughout the temperature range of 20° C. to 80° C., or a liquidthroughout the temperature range of −20° C. to 100° C. In otherembodiments, the catalyst deactivating agent can be a liquid throughoutthe temperature range of 0° C. to 100° C., the temperature range of 20°C. to 120° C., the temperature range of 30° C. to 120° C., or thetemperature range of 30° C. to 150° C.

The catalyst deactivating agent can be miscible with and/or soluble in ahydrocarbon solvent. For instance, the catalyst deactivating agent canbe miscible with and/or soluble in a hydrocarbon solvent comprising (orconsisting essentially of, or consisting of) a C₃ to C₁₀ hydrocarbon;alternatively, a C₃ to C₁₀ aliphatic hydrocarbon; alternatively, a C₃ toC₈ aliphatic hydrocarbon; or alternatively, a C₄ to C₈ aliphatichydrocarbon. The aliphatic hydrocarbon can be cyclic or acyclic and/orcan be linear or branched, unless otherwise specified. Illustrativealiphatic hydrocarbon solvents can include, but are not limited to,propane, isobutane, n-butane, n-pentane, isopentane, neopentane,n-hexane, heptane, octane, cyclohexane, cycloheptane, methylcyclohexane,methylcycloheptane, and the like, including mixtures or combinationsthereof.

Furthermore, the catalyst deactivating agent can be miscible with and/orsoluble in a hydrocarbon solvent comprising (or consisting essentiallyof, or consisting of) a C₆ to C₁₀ aromatic hydrocarbon or,alternatively, a C₆ to C₈ aromatic hydrocarbon. Illustrative aromatichydrocarbon solvents can include, but are not limited to, benzene,toluene, xylene, ethylbenzene, and the like, including mixtures orcombinations thereof.

In one embodiment, the catalyst deactivating agent can be miscible withand/or soluble in propane, isobutane, n-butane, n-pentane, isopentane,neopentane, n-hexane, heptane, octane, cyclohexane, cycloheptane,methylcyclohexane, methylcycloheptane, benzene, toluene, xylene, orethylbenzene, or a mixture thereof. In another embodiment, the catalystdeactivating agent can be miscible with and/or soluble in propane,cyclohexane, isobutane, n-butane, n-pentane, isopentane, neopentane, orn-hexane, or a mixture thereof. In yet another embodiment, the catalystdeactivating agent can be miscible with and/or soluble in propane;alternatively, isobutane; alternatively, n-butane; alternatively,n-pentane; alternatively, isopentane; alternatively, neopentane;alternatively, n-hexane; alternatively, heptane; alternatively, octane;alternatively, cyclohexane; alternatively, cycloheptane; alternatively,methylcyclohexane; alternatively, methylcycloheptane; alternatively,benzene; alternatively, toluene; alternatively, xylene; oralternatively, ethylbenzene.

Applicants also contemplate that the catalyst deactivating agent can bemiscible with and/or soluble in an ISOPAR® mixed aliphatic hydrocarbonsolvent, such as, for example, ISOPAR® C, ISOPAR® E, ISOPAR® G, ISOPAR®H, ISOPAR® L, ISOPAR® M, or a mixture thereof.

Catalyst Systems

The methods disclosed herein are not limited to any particulartransition-metal based catalyst system suitable for the polymerizationof an olefin monomer. The transition-metal based catalyst system cancomprise, for example, a transition metal (one or more than one) fromGroups IIIB-VIIIB of the Periodic Table of the Elements. In oneembodiment, the transition metal-based catalyst system can comprise aGroup III, IV, V, or VI transition metal, or a combination of two ormore transition metals. The transition metal-based catalyst system cancomprise chromium, titanium, zirconium, hafnium, vanadium, or acombination thereof, or can comprise chromium, titanium, zirconium,hafnium, or a combination thereof, in other embodiments. Accordingly,the transition metal-based catalyst system can comprise chromium, ortitanium, or zirconium, or hafnium, either singly or in combination.

Various transition metal-based catalyst systems known to a skilledartisan are useful in the polymerization of olefins. These include, butare not limited to, Ziegler-Natta based catalyst systems (e.g.,Ziegler-based catalyst systems), chromium-based catalyst systems,metallocene-based catalyst systems, Phillips catalyst systems, Ballardcatalyst systems, coordination compound catalyst systems,post-metallocene catalyst systems, and the like, including combinationsthereof. The methods disclosed herein are not limited to theaforementioned catalyst systems, but Applicants nevertheless contemplateparticular embodiments directed to these catalyst systems, as well as todual catalyst or multi-catalyst combinations. For instance, thetransition metal-based catalyst system can be a Ziegler-Natta basedcatalyst system, a chromium-based catalyst system, and/or ametallocene-based catalyst system; alternatively, a Ziegler-Natta basedcatalyst system; alternatively, a chromium-based catalyst system; oralternatively, a metallocene-based catalyst system. Examples ofrepresentative and non-limiting transition metal-based catalysts systemsinclude those disclosed in the U.S. Pat. Nos. 3,887,494, 3,119,569,4,053,436, 4,981,831, 4,364,842, 4,444,965, 4,364,855, 4,504,638,4,364,854, 4,444,964, 4,444,962, 3,976,632, 4,248,735, 4,297,460,4,397,766, 2,825,721, 3,225,023, 3,226,205, 3,622,521, 3,625,864,3,900,457, 4,301,034, 4,547,557, 4,339,559, 4,806,513, 5,037,911,5,219,817, 5,221,654, 4,081,407, 4,296,001, 4,392,990, 4,405,501,4,151,122, 4,247,421, 4,460,756, 4,182,815, 4,735,931, 4,820,785,4,988,657, 5,436,305, 5,610,247, 5,627,247, 3,242,099, 4,808,561,5,275,992, 5,237,025, 5,244,990, 5,179,178, 4,855,271, 5,179,178,5,275,992, 3,900,457, 4,939,217, 5,210,352, 5,436,305, 5,401,817,5,631,335, 5,571,880, 5,191,132, 5,480,848, 5,399,636, 5,565,592,5,347,026, 5,594,078, 5,498,581, 5,496,781, 5,563,284, 5,554,795,5,420,320, 5,451,649, 5,541,272, 5,705,478, 5,631,203, 5,654,454,5,705,579, 5,668,230, 6,300,271, 6,831,141, 6,653,416, 6,613,712,7,294,599, 6,355,594, 6,395,666, 6,833,338, 7,417,097, 6,548,442, and7,312,283, each of which is incorporated herein by reference in itsentirety.

While not intending to be bound by theory, the catalyst deactivatingagent may reduce the catalyst activity of the transition metal-catalystsystem and/or reduce the production rate of the olefin polymer byneutralizing or interacting with the transition metal present in thetransition metal-based catalyst system. In catalyst systems that containa co-catalyst, the catalyst deactivating agent may additionally reducethe catalyst activity of the transition metal-catalyst system and/orreduce the production rate of the olefin polymer by neutralizing orinteracting with the co-catalyst present in the transition metal-basedcatalyst system, although this is not a requirement.

Commonly used polymerization co-catalysts can include, but are notlimited to, metal alkyl, or organometal, co-catalysts, with the metalencompassing boron, aluminum, and the like. For instance, alkyl boronand/or alkyl aluminum compounds often can be used as co-catalysts in atransition metal-based catalyst system. Representative compounds caninclude, but are not limited to, tri-n-butyl borane, tripropylborane,triethylborane, triethylaluminum, triisobutylaluminum, diethylaluminumchloride, and the like, including combinations thereof.

Olefin Monomers

Olefin monomers contemplated herein typically include olefin compoundshaving from 2 to 30 carbon atoms per molecule and having at least oneolefinic double bond. Homopolymerization processes using a singleolefin, such as ethylene, propylene, butene, hexene, octene, and thelike, are encompassed, as well as copolymerization, terpolymerization,etc., reactions using an olefin monomer with at least one differentolefinic compound. As previously disclosed, polymerization processes aremeant to encompass oligomerization processes as well.

As an example, any resultant ethylene copolymers, terpolymers, etc.,generally can contain a major amount of ethylene (>50 mole percent) anda minor amount of comonomer (<50 mole percent). Comonomers that can becopolymerized with ethylene often have from 3 to 20 carbon atoms intheir molecular chain.

Acyclic, cyclic, polycyclic, terminal (a), internal, linear, branched,substituted, unsubstituted, functionalized, and non-functionalizedolefins can be employed. For example, typical unsaturated compounds thatcan be polymerized to produce olefin polymers can include, but are notlimited to, ethylene, propylene, 1-butene, 2-butene, 3-methyl-1-butene,isobutylene, 1-pentene, 2-pentene, 3-methyl-1-pentene,4-methyl-1-pentene, 1-hexene, 2-hexene, 3-hexene, 3-ethyl-1-hexene,1-heptene, 2-heptene, 3-heptene, the four normal octenes (e.g.,1-octene), the four normal nonenes, the five normal decenes, and thelike, or mixtures of two or more of these compounds. Cyclic and bicyclicolefins, including but not limited to, cyclopentene, cyclohexene,norbornylene, norbornadiene, and the like, also can be polymerized asdescribed herein. Styrene also can be employed as a monomer or as acomonomer. In an embodiment, the olefin monomer can be a C₂-C₂₀ olefin;alternatively, a C₂-C₁₂ olefin; alternatively, a C₂-C₁₀ α-olefin;alternatively, ethylene, propylene, 1-butene, 1-hexene, or 1-octene;alternatively, ethylene or propylene; alternatively, ethylene; oralternatively, propylene.

When a copolymer (or alternatively, a terpolymer) is desired, the olefinmonomer can be, for example, ethylene or propylene, which iscopolymerized with at least one comonomer. According to one embodiment,the olefin monomer in the polymerization process can be ethylene. Inthis embodiment, examples of suitable olefin comonomers can include, butare not limited to, propylene, 1-butene, 2-butene, 3-methyl-1-butene,isobutylene, 1-pentene, 2-pentene, 3-methyl-1-pentene,4-methyl-1-pentene, 1-hexene, 2-hexene, 3-ethyl-1-hexene, 1-heptene,2-heptene, 3-heptene, 1-octene, 1-decene, styrene, and the like, orcombinations thereof. According to one embodiment, the comonomer cancomprise an α-olefin, while in another embodiment, the comonomer cancomprise 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, styrene, orany combination thereof.

Generally, the amount of comonomer introduced into a polymerizationreactor to produce the copolymer can be from about 0.01 to about 50weight percent of the comonomer based on the total weight of the monomerand comonomer. According to another embodiment, the amount of comonomerintroduced into a polymerization reactor can be from about 0.01 to about40 weight percent comonomer based on the total weight of the monomer andcomonomer. In still another embodiment, the amount of comonomerintroduced into a polymerization reactor can be from about 0.1 to about35 weight percent comonomer based on the total weight of the monomer andcomonomer. Yet, in another embodiment, the amount of comonomerintroduced into a polymerization reactor can be from about 0.5 to about20 weight percent comonomer based on the total weight of the monomer andcomonomer.

While not intending to be bound by this theory, where branched,substituted, or functionalized olefins are used as reactants, it isbelieved that a steric hindrance can impede and/or slow thepolymerization reaction. Thus, branched and/or cyclic portion(s) of theolefin removed somewhat from the carbon-carbon double bond would not beexpected to hinder the reaction in the way that the same olefinsubstituents situated more proximate to the carbon-carbon double bondmight.

According to one embodiment, at least one monomer/reactant can beethylene, so the polymerization reaction can be a homopolymerizationinvolving only ethylene, or a copolymerization with a different acyclic,cyclic, terminal, internal, linear, branched, substituted, orunsubstituted olefin. In addition, the methods disclosed herein intendfor olefin to also encompass diolefin compounds that include, but arenot limited to, 1,3-butadiene, isoprene, 1,4-pentadiene, 1,5-hexadiene,and the like.

Olefin polymers encompassed herein can include any polymer (or oligomer)produced from any olefin monomer (and optional comonomer(s)) describedherein. For example, the olefin polymer can comprise an ethylenehomopolymer, a propylene homopolymer, an ethylene copolymer (e.g.,ethylene/1-butene, ethylene/1-hexene, ethylene/1-octene, etc.), apropylene copolymer, an ethylene terpolymer, a propylene terpolymer, andthe like, including combinations thereof.

Polymerization Reactor Systems

The disclosed methods are intended for any olefin polymerization processusing various types of polymerization reactors, polymerization reactorsystems, and polymerization reaction conditions. As used herein,“polymerization reactor” includes any polymerization reactor capable ofpolymerizing (inclusive of oligomerizing) olefin monomers and comonomers(one or more than one comonomer) to produce homopolymers, copolymers,terpolymers, and the like. The various types of polymerization reactorsinclude those that can be referred to as a batch reactor, slurryreactor, gas-phase reactor, solution reactor, high pressure reactor,tubular reactor, autoclave reactor, and the like, or combinationsthereof. The polymerization conditions for the various reactor types arewell known to those of skill in the art. Gas phase reactors can comprisefluidized bed reactors or staged horizontal reactors. Slurry reactorscan comprise vertical or horizontal loops. High pressure reactors cancomprise autoclave or tubular reactors. Reactor types can include batchor continuous processes. Continuous processes could use intermittent orcontinuous product discharge. Polymerization reactor systems andprocesses also can include partial or full direct recycle of unreactedmonomer, unreacted comonomer, and/or diluent.

A polymerization reactor system can comprise one type of reactor ormultiple reactors of the same or different type. For instance, thepolymerization reactor system can comprise a slurry reactor, a gas-phasereactor, a solution reactor, or a combination of two or more of thesereactors. Production of polymers in multiple reactors can includeseveral stages in at least two separate polymerization reactorsinterconnected by a transfer device making it possible to transfer thepolymers resulting from the first polymerization reactor into the secondreactor. The desired polymerization conditions in one of the reactorscan be different from the operating conditions of the other reactor(s).Alternatively, polymerization in multiple reactors can include themanual transfer of polymer from one reactor to subsequent reactors forcontinued polymerization. Multiple reactor systems can include anycombination including, but not limited to, multiple loop reactors,multiple gas phase reactors, a combination of loop and gas phasereactors, multiple high pressure reactors, or a combination of highpressure with loop and/or gas phase reactors. The multiple reactors canbe operated in series, in parallel, or both.

According to one embodiment, the polymerization reactor system cancomprise at least one loop slurry reactor comprising vertical orhorizontal loops. Monomer, diluent, catalyst, and comonomer can becontinuously fed to a loop reactor where polymerization occurs.Generally, continuous processes can comprise the continuous introductionof monomer/comonomer, a catalyst, and a diluent into a polymerizationreactor and the continuous removal from this reactor of a suspensioncomprising polymer particles and the diluent. Reactor effluent can beflashed to remove the solid polymer from the liquids that comprise thediluent, monomer and/or comonomer. Various technologies can be used forthis separation step including, but not limited to, flashing that caninclude any combination of heat addition and pressure reduction;separation by cyclonic action in either a cyclone or hydrocyclone; orseparation by centrifugation.

A typical slurry polymerization process (also known as the particle formprocess) is disclosed, for example, in U.S. Pat. Nos. 3,248,179,4,501,885, 5,565,175, 5,575,979, 6,239,235, 6,262,191, and 6,833,415,each of which is incorporated herein by reference in its entirety.

Suitable diluents used in slurry polymerization include, but are notlimited to, the monomer being polymerized and hydrocarbons that areliquids under reaction conditions. Examples of suitable diluentsinclude, but are not limited to, hydrocarbons such as propane,cyclohexane, isobutane, n-butane, n-pentane, isopentane, neopentane, andn-hexane. Some loop polymerization reactions can occur under bulkconditions where no diluent is used. An example is polymerization ofpropylene monomer as disclosed in U.S. Pat. No. 5,455,314, which isincorporated by reference herein in its entirety.

According to yet another embodiment, the polymerization reactor systemcan comprise at least one gas phase reactor (e.g., a fluidized bedreactor). Such reactor systems can employ a continuous recycle streamcontaining one or more monomers continuously cycled through a fluidizedbed in the presence of the catalyst under polymerization conditions. Arecycle stream can be withdrawn from the fluidized bed and recycled backinto the reactor. Simultaneously, polymer product can be withdrawn fromthe reactor and new or fresh monomer can be added to replace thepolymerized monomer. Such gas phase reactors can comprise a process formulti-step gas-phase polymerization of olefins, in which olefins arepolymerized in the gaseous phase in at least two independent gas-phasepolymerization zones while feeding a catalyst-containing polymer formedin a first polymerization zone to a second polymerization zone. One typeof gas phase reactor is disclosed in U.S. Pat. Nos. 5,352,749,4,588,790, and 5,436,304, each of which is incorporated by reference inits entirety herein.

According to still another embodiment, the polymerization reactor systemcan comprise a high pressure polymerization reactor, e.g., can comprisea tubular reactor or an autoclave reactor. Tubular reactors can haveseveral zones where fresh monomer, initiators, or catalysts are added.Monomer can be entrained in an inert gaseous stream and introduced atone zone of the reactor. Initiators, catalysts, and/or catalystcomponents can be entrained in a gaseous stream and introduced atanother zone of the reactor. The gas streams can be intermixed forpolymerization. Heat and pressure can be employed appropriately toobtain optimal polymerization reaction conditions.

According to yet another embodiment, the polymerization reactor systemcan comprise a solution polymerization reactor wherein themonomer/comonomer are contacted with the catalyst composition bysuitable stirring or other means. A carrier comprising an inert organicdiluent or excess monomer can be employed. If desired, themonomer/comonomer can be brought in the vapor phase into contact withthe catalytic reaction product, in the presence or absence of liquidmaterial. The polymerization zone can be maintained at temperatures andpressures that will result in the formation of a solution of the polymerin a reaction medium. Agitation can be employed to obtain bettertemperature control and to maintain uniform polymerization mixturesthroughout the polymerization zone. Adequate means are utilized fordissipating the exothermic heat of polymerization.

The polymerization reactor system can further comprise any combinationof at least one raw material feed system, at least one feed system forcatalyst or catalyst components, and/or at least one polymer recoverysystem. Suitable reactor systems can further comprise systems forfeedstock purification, catalyst storage and preparation, extrusion,reactor cooling, polymer recovery, fractionation, recycle, storage,loadout, laboratory analysis, and process control. Depending upon thedesired properties of the olefin polymer, hydrogen can be added to thepolymerization reactor as needed (e.g., continuously, pulsed, etc.).

Polymerization conditions that are controlled for efficiency and toprovide desired polymer properties can include temperature, pressure,and the concentrations of various reactants. Polymerization temperaturecan affect catalyst productivity, polymer molecular weight, andmolecular weight distribution. A suitable polymerization temperature canbe any temperature below the de-polymerization temperature according tothe Gibbs Free energy equation. Typically, this includes from about 60°C. to about 280° C., for example, or from about 60° C. to about 110° C.,depending upon the type of polymerization reactor. In some reactorsystems, the polymerization temperature generally can be within a rangefrom about 70° C. to about 90° C., or from about 75° C. to about 85° C.

Suitable pressures will also vary according to the reactor andpolymerization type. The pressure for liquid phase polymerizations in aloop reactor typically can be less than 1000 psig. The pressure for gasphase polymerization can be in the 200 to 500 psig range. High pressurepolymerization in tubular or autoclave reactors generally can beconducted at about 20,000 to 75,000 psig. Polymerization reactors alsocan be operated in a supercritical region occurring at generally highertemperatures and pressures. Operation above the critical point of apressure/temperature diagram (supercritical phase) can offer advantages.

Compositions Containing a Catalyst Deactivating Agent

In accordance with certain embodiments, compositions containing acatalyst deactivating agent are provided, and such compositions cancomprise (or consist essentially of, or consist of) a catalystdeactivating agent and a C₃ to C₁₈ hydrocarbon solvent. The catalystdeactivating agent can comprise a natural source oil, a siloxane, or acombination thereof, e.g., any natural source oil or siloxane describedherein. In some embodiments, the composition can be a compositionsuitable for introduction or direct injection into a polymerizationreactor system (e.g., for reducing catalyst activity and/or polymerproduction rate). As noted hereinabove, the catalyst deactivating agentcan be introduced into the polymerization reactor, or into thepolymerization reactor system downstream of the polymerization reactor,in a composition along with a C₃ to C₁₈ hydrocarbon solvent (e.g., amixture, solution, suspension, etc.). The properties of the compositioncontaining the catalyst deactivating agent and the C₃ to C₁₈ hydrocarbonsolvent can be varied to ensure compatibility in the polymerizationreactor system, as well as an overall composition viscosity that allowseasy introduction into the reactor system and distribution throughoutthe reactor system.

Generally, the hydrocarbon solvent can comprise an aliphatichydrocarbon, an aromatic hydrocarbon, or a combination thereof;alternatively, an aliphatic hydrocarbon; or alternatively, an aromatichydrocarbon. Suitable aliphatic hydrocarbons which can be useful as thehydrocarbon solvent can include C₃ to C₁₈ aliphatic hydrocarbons;alternatively, C₄ to C₁₀ aliphatic hydrocarbons; or alternatively, C₄ toC₈ aliphatic hydrocarbons. The aliphatic hydrocarbons can be cyclic oracyclic and/or can be linear or branched, unless otherwise specified.Non-limiting examples of suitable acyclic aliphatic hydrocarbon solventsthat can be utilized singly or in any combination can include propane,iso-butane, n-butane, butane (n-butane or a mixture of linear andbranched C₄ acyclic aliphatic hydrocarbons), pentane (n-pentane or amixture of linear and branched C₅ acyclic aliphatic hydrocarbons),hexane (n-hexane or mixture of linear and branched C₆ acyclic aliphatichydrocarbons), heptane (n-heptane or mixture of linear and branched C₇acyclic aliphatic hydrocarbons), octane (n-octane or a mixture of linearand branched C₈ acyclic aliphatic hydrocarbons), and the like, orcombinations thereof; alternatively, iso-butane, n-butane, butane(n-butane or a mixture of linear and branched C₄ acyclic aliphatichydrocarbons), pentane (n-pentane or a mixture of linear and branched C₅acyclic aliphatic hydrocarbons), hexane (n-hexane or mixture of linearand branched C₆ acyclic aliphatic hydrocarbons), heptane (n-heptane ormixture of linear and branched C₇ acyclic aliphatic hydrocarbons),octane (n-octane or a mixture of linear and branched C₈ acyclicaliphatic hydrocarbons), or combinations thereof; alternatively, butane(n-butane or a mixture of linear and branched C₄ acyclic aliphatichydrocarbons), pentane (n-pentane or a mixture of linear and branched C₅acyclic aliphatic hydrocarbons), hexane (n-hexane or mixture of linearand branched C₆ acyclic aliphatic hydrocarbons), heptane (n-heptane ormixture of linear and branched C₇ acyclic aliphatic hydrocarbons),octane (n-octane or a mixture of linear and branched C₈ acyclicaliphatic hydrocarbons), or combinations thereof; alternatively,propane; alternatively, iso-butane; alternatively, n-butane;alternatively, butane (n-butane or a mixture of linear and branched C₄acyclic aliphatic hydrocarbons); alternatively, pentane (n-pentane or amixture of linear and branched C₅ acyclic aliphatic hydrocarbons);alternatively, hexane (n-hexane or mixture of linear and branched C₆acyclic aliphatic hydrocarbons); alternatively, heptane (n-heptane ormixture of linear and branched C₇ acyclic aliphatic hydrocarbons); oralternatively, octane (n-octane or a mixture of linear and branched C₈acyclic aliphatic hydrocarbons).

Non-limiting examples of suitable cyclic aliphatic hydrocarbon solventscan include, but are not limited to, cyclopentane, cyclohexane, methylcyclopentane, methyl cyclohexane, and the like, or combinations thereof;alternatively, cyclopentane; alternatively, cyclohexane; alternatively,methyl cyclopentane; or alternatively, methyl cyclohexane. Aromatichydrocarbons which can be useful as the hydrocarbon solvent can includeC₆ to C₁₈ aromatic hydrocarbons or, alternatively, C₆ to C₁₀ aromatichydrocarbons. Non-limiting examples of suitable aromatic hydrocarbonsthat can be utilized singly or in any combination can include, but arenot limited to, benzene, toluene, xylene (including ortho-xylene,meta-xylene, para-xylene, or mixtures thereof), ethylbenzene, and thelike, or combinations thereof; alternatively, benzene; alternatively,toluene; alternatively, xylene (including ortho-xylene, meta-xylene,para-xylene or mixtures thereof); or alternatively, ethylbenzene.

In one embodiment, the hydrocarbon solvent can comprise (or consistessentially of, or consist of) propane, isobutane, n-butane, n-pentane,isopentane, neopentane, n-hexane, n-heptane, n-octane, cyclopentane,cyclohexane, cycloheptane, methylcyclopentane, methylcyclohexane,methylcycloheptane, benzene, toluene, xylene, ethylbenzene, or a mixturethereof. In another embodiment, the hydrocarbon solvent can comprisepropane, isobutane, n-butane, n-pentane, isopentane, neopentane,n-hexane, heptane, octane, cyclohexane, cycloheptane, methylcyclohexane,methylcycloheptane, benzene, toluene, xylene, ethylbenzene, or a mixturethereof. Yet, in another embodiment, the hydrocarbon solvent cancomprise propane; alternatively, isobutane; alternatively, n-butane;alternatively, n-pentane; alternatively, isopentane; alternatively,neopentane; alternatively, n-hexane; alternatively, heptane;alternatively, octane; alternatively, cyclohexane; alternatively,cycloheptane; alternatively, methylcyclohexane; alternatively,methylcycloheptane; alternatively, benzene; alternatively, toluene;alternatively, xylene; or alternatively, ethylbenzene.

Certain compositions can comprise a catalyst deactivating agent and a C₃to C₁₈ hydrocarbon solvent. Consistent with embodiments disclosed herein(and the particularities of the polymerization reaction system, thecatalyst deactivating agent, the hydrocarbon solvent, etc.), the weightratio of the hydrocarbon solvent to the catalyst deactivating agent inthese compositions can be in a range from about 1000:1 to about 1:100,such as, for example, from about 750:1 to about 1:75, from about 500:1to about 1:50, from about 250:1 to about 1:25, from about 100:1 to about1:10, from about 50:1 to about 1:5, or from about 30:1 to about 1:3, andthe like.

EXAMPLES

The invention is further illustrated by the following examples, whichare not to be construed in any way as imposing limitations to the scopeof this invention. Various other aspects, embodiments, modifications,and equivalents thereof which, after reading the description herein, cansuggest themselves to one of ordinary skill in the art without departingfrom the spirit of the present invention or the scope of the appendedclaims.

Example 1

Addition of a Corn Oil Catalyst Deactivating Agent into a PolymerizationReaction Using a Chromium-Based Catalyst System.

The chromium-based catalyst system used in Example 1 was Magnapore 963,commercially available from W. R. Grace, and activated at approximately870° C.

The polymerization run was conducted in a 2.2-L steel reactor equippedwith a marine stirrer rotating at 500 rpm. The reactor was equipped witha temperature jacket and control system to maintain substantiallyconstant temperature (+/−0.5° C.). A small amount of the solid chromiumcatalyst (0.144 g of the catalyst, which contained 1 wt. % Cr) was firstcharged under nitrogen to the dry reactor. Next, 1 L of isobutane liquidwas charged, and the reactor heated up to 105° C. When co-catalysts wereused, such as triethylaluminum (TEA), 1 mL of a 0.5 wt. % co-catalystsolution in heptane was added midway during the isobutane addition.Finally, ethylene was added to the reactor to a pressure of about 550psig, which was maintained throughout the polymerization run. Thereaction rate was determined by recording the flow of ethylene into thereactor required to maintain the fixed reactor pressure.

In Example 1, the corn oil catalyst deactivating agent was injected intothe reactor during the run as follows. First, a corn oil solution wasprepared by mixing 1 mL of corn oil, an edible grade available fromMazola, with 50 mL of n-heptane that was previously dried under 13×molecular sieve. After the polymerization was started, it was allowed tocontinue for about 18 min, long enough to reach peak activity. Then, 1mL of the corn oil/n-heptane solution was added to the reactor asfollows. The reactor first was closed so that the ethylene feed wasstopped. Then, the pressure was decreased by bleeding off enough gas tolower the pressure to about 250 psig. Next, 1 mL of the cornoil/n-heptane solution was injected into an entry port which wassimultaneously purged with isobutane vapor, then closed and re-filledwith isobutane liquid. The port was re-pressurized with ethylene to 550psig. The pressurized port was then opened to the reactor, so that thecorn oil was immediately flushed with about 125 mL of isobutane into thereactor, followed by resuming ethylene addition at 550 psig.

The effect of the corn oil was immediately noticed by a drop in heatproduced (as monitored by the difference in temperature between thejacket temperature and the reactor temperature), as well a rapid drop inthe ethylene flow into the reactor. It usually took a few minutes toequalize the pressure between the reactor and the entry port, so thatthe ethylene flow continued for a few minutes, even though thepolymerization reaction was terminated. Hence, the configuration of thereactor, and the method of injecting the corn oil into the reactor,resulted in continued ethylene flow for a few minutes, even after thereaction had been terminated. Applicants believe, based on the reactiondata in FIG. 1 and the drop in heat production, that once the corn oilwas in contact with the catalyst, the “kill” or termination of thereaction was extremely rapid, i.e., substantially instantaneous.

FIG. 1 graphically illustrates Example 1. The reaction rate listed,abbreviated gPE/g/h, was the grams of polyethylene produced per gram ofthe chromium catalyst system per hour. FIG. 1 demonstrates that anatural source oil, such as corn oil, can be very effective at reducingthe catalyst activity and/or the reaction rate, as well as completelyterminating a polymerization reaction. Additionally, very low amounts ofthe corn oil, based on the amount of the catalyst system (or thetransition metal in the catalyst system), were required.

Example 2

Addition of a Corn Oil Catalyst Deactivating Agent into a PolymerizationReaction Using a Chromium-Based Catalyst System in Combination with aTriethylaluminum Co-Catalyst.

Example 2 was conducted in substantially the same manner as Example 1,except that 1 mL of 0.5 wt. % TEA co-catalyst solution was also added tothe reactor, midway through the isobutane addition. About 0.077 grams ofthe same Magnapore catalyst was added to the reactor, followed by theother reactants, as described in Example 1. Then, about 17 min into thepolymerization run, when the reaction rate had peaked, 1 mL of the samecorn oil solution (in n-heptane) was injected into the reactor as thecatalyst deactivating agent.

FIG. 2 graphically illustrates Example 2, with the reaction rate listed(gPE/g/h) being the grams of polyethylene produced per gram of thechromium catalyst system per hour. FIG. 2 demonstrates that a naturalsource oil, such as corn oil, can be very effective at reducing thecatalyst activity and/or the reaction rate, even in the presence of aco-catalyst, as well as completely terminating a polymerizationreaction. Additionally, very low amounts of the corn oil, based on theamount of the catalyst system (or the transition metal in the catalystsystem), were required.

Example 3

Addition of a 100 cSt Polydimethylsiloxane Catalyst Deactivating Agentinto a Polymerization Reaction Using a Chromium-Based Catalyst System inCombination with a Triethylaluminum Co-Catalyst.

Example 3 was conducted in the substantially the same manner as Example1, except that a 100 cSt siloxane was injected into the reactor as thecatalyst deactivating agent. Approximately 0.27 g of the same Magnaporecatalyst described in Example 1 were charged into the reactor, and 1 mLof the 0.5 wt. % TEA solution was charged to the reactor midway betweenthe isobutane addition. After about 7 min into the polymerization run,1.8 mL of an n-heptane solution containing 2.116×10⁻³ g of siloxane permL were injected into the reactor. As soon as the siloxane wasintroduced into the reactor, there was an immediate and significant dropin the polymerization rate, as evidenced by the drop in the ethyleneflow rate and in heat production. After about 10 min, the reaction ratewas effectively zero.

FIG. 3 graphically illustrates Example 3, with the reaction rate listed(gPE/g/h) being the grams of polyethylene produced per gram of thechromium catalyst system per hour. FIG. 3 demonstrates that a siloxane,such as a polydimethylsiloxane with a viscosity of 100 cSt, can be veryeffective at reducing the catalyst activity and/or the reaction rate, aswell as completely terminating a polymerization reaction. Additionally,very low amounts of the siloxane, based on the amount of the catalystsystem, were required.

Constructive Examples 4-5

Constructive Addition of a Catalyst Deactivating Agent into aPolymerization Reaction Using a Ziegler-Natta Catalyst System.

The polymerizations of Constructive Examples 4-5 can be conducted in a2.2-L reactor as described in Examples 1-3. The reactor can be preparedfor use by purging with nitrogen and heating the empty reactor to 110°C. After cooling to below 40° C. and purging with isobutane vapor, 1 mLof 15 weight % TEA (triethylaluminum) in heptane, about 100 mg of aZiegler-Natta catalyst (e.g., such as W. R. Grace 5951, but not limitedthereto) which can contain 0.8 wt. % Ti, and 1.2 L of isobutane areadded. The contents are mixed at 500 rpm and are heated to near thetarget polymerization temperature of 105° C., and can be maintained atthat temperature for the duration of the run. Ethylene is then added andcan be fed on demand to maintain the total pressure at 500 psig.

In Constructive Example 4, the catalyst deactivating agent is a soybeanoil, while in Constructive Example 5, the catalyst deactivating agent isa polydimethylsiloxane having a viscosity at 25° C. of 250 cSt. Therespective catalyst deactivating agent can be injected into the reactormidway through the run as follows. First, the reactor is closed so thatthe ethylene feed is stopped. Then, the pressure is decreased bybleeding off enough gas to lower the pressure to about 250 psig. Next,the catalyst deactivating agent, either neat or in a solution inn-heptane, is injected into an entry port which can be simultaneouslypurged with isobutane vapor, then closed and re-filled with isobutaneliquid. The port is re-pressurized with ethylene to 500 psig. Thepressurized port is then opened to the reactor, so that the catalystdeactivating agent is immediately flushed with about 125 mL of isobutaneinto the reactor, followed by resuming ethylene addition to 300 psig. InConstructive Example 4, the soybean oil is added at 0.2 g of soybean oilper g of the Ziegler-Natta catalyst. In Constructive Example 5, 0.2 g ofthe 250 cSt polydimethylsiloxane are added to produce a weight ratio ofthe siloxane to Ti in the Ziegler-Natta based catalyst system of 250.

The effect of the catalyst deactivating agent is immediately noticed bya drop in heat produced (as monitored by the difference in temperaturebetween the jacket temperature and the reactor temperature). It usuallymay take a few minutes to equalize the pressure between the reactor andthe entry port, so the ethylene flow can be continued for a few minutes.By monitoring the polymerization reaction rate over time, in grams ofpolyethylene produced per gram of the Ziegler-Natta catalyst system perhour, it is expected that the addition of the catalyst deactivatingagent will rapidly inhibit the polymerization reaction, even at the verylow addition levels.

Constructive Example 6

Constructive Addition of a Catalyst Deactivating Agent into aPolymerization Reaction Using a Metallocene-Based Catalyst System.

The polymerization of Constructive Example 6 can be conducted in aone-gallon (3.785-L) stainless steel reactor. Metallocene solutions (1mg/mL) can be prepared by dissolving 30 mg of the metallocene in 30 mLof toluene. In Constructive Example 6, the catalyst deactivating agentis a canola oil. The catalyst deactivating agent can be injected neat,or in a solution prepared by dissolving the respective deactivatingagent in an appropriate amount of heptanes.

A typical experimental procedure is as follows. Alkyl aluminum solution(0.5 mmol triisobutylaluminum), bromide-treated zinc/alumina (150 mg),and the metallocene solution (2 mg metallocene) are added in that orderthrough a charge port while venting isobutane vapor. The aluminum totransition metal (Zr) ratio is approximately 146:1. The charge port isclosed and about 1.8 L of isobutane are added. The contents of thereactor are stirred and heated to the desired run temperature of 90° C.,which can be maintained constant via an automated heating-coolingsystem. Ethylene is continuously fed with an automated feeding system ondemand to maintain the 390 psig pressure for the duration of thepolymerization run. After the polymerization reaction is established,the catalyst deactivating agent is introduced into the reactor with highpressure ethylene injection. The metallocene compound used in thisConstructive Example can have the following structure, but is notlimited thereto:

In Constructive Example 6, the canola oil is added at 0.25 grams ofcanola oil per gram of the metallocene compound. By monitoring thepolymerization reaction rate over time, in kilograms of polyethyleneproduced per gram of the metallocene component of the catalyst systemper hour, it is expected that the addition of the catalyst deactivatingagent will rapidly terminate the polymerization reaction, even at thevery low addition levels.

Examples 7-9

Reactor System Simulations Demonstrating that the Catalyst DeactivatingAgent Remains with the Polymer Stream.

Simulation studies were conducted in loop slurry reactor systems todetermine whether the catalyst deactivating agent will remain with thepolymer stream exiting the reactor system. Three different plant systemswere modeled, using either a high density polyethylene (HDPE) product ora linear low density polyethylene (LLDPE) product. Various weight ratiosof polymer production rate to catalyst feed rate, of catalyst feed rateto deactivating agent feed rate, and of polymer production rate toisobutane (slurry diluent) recycle rate were simulated, as summarized inTable I. Reactor effluent leaving the reactor included, for example,polymer product, catalyst deactivating agent, isobutane diluent,ethylene, and 1-hexene (if used). In the simulation, the effluententered a flash tank at a pressure of about 180-230 psig, and thenentered a purge column at a pressure of around atmospheric pressure.

SIL-1 was a 45 cSt mixed phenylmethyl-dimethyl cyclosiloxane, SIL-2 wasa 38 cSt tetramethyltetraphenyltrisiloxane, and SIL-3 was a 175 cSttrimethylpentaphenyltrisiloxane. For each of the simulations of Examples7-9 and each of the respective catalyst deactivating agents, 100% of thecatalyst deactivating agent remained with the polymer product streamafter passing through the flash tank and purge column, and 0% waspresent in the isobutane recycle stream.

TABLE I Examples 7-9. Catalyst Ratio of Production Ratio of CatalystFeed Ratio of Production Deactivating Rate to Catalyst Rate toDeactivating Rate to Isobutane Example Plant Product Agent Feed RateAgent Feed Rate Recycle Rate 7 A HDPE SIL-1, 2 or 3 1940:1 3.8:1 1.2:1 8B LLDPE SIL-1, 2 or 3 2250:1 3.8:1 0.9:1 9 C HDPE SIL-1, 2 or 3 4420:13.8:1 1.1:1

The invention has been described above with reference to numerousembodiments and specific examples. Many variations will suggestthemselves to those skilled in the art in light of the above detaileddescription. All such obvious variations are within the full intendedscope of the appended claims. Other embodiments of the invention caninclude, but are not limited to, the following:

Embodiment 1

A method of controlling a polymerization reaction in a polymerizationreactor system, the method comprising:

-   -   (i) introducing a transition metal-based catalyst system, an        olefin monomer, and optionally an olefin comonomer into a        polymerization reactor within the polymerization reactor system;    -   (ii) contacting the transition metal-based catalyst system with        the olefin monomer and the optional olefin comonomer under        polymerization conditions to produce an olefin polymer; and    -   (iii) introducing a catalyst deactivating agent into the        polymerization reactor system to partially or completely        terminate the polymerization reaction in the polymerization        reactor system;        wherein the catalyst deactivating agent comprises a natural        source oil, a siloxane, or a combination thereof.

Embodiment 2

The method defined in embodiment 1, wherein the catalyst deactivatingagent is introduced into the polymerization reactor to partially orcompletely terminate the polymerization reaction in the polymerizationreactor.

Embodiment 3

The method defined in embodiment 1, wherein the catalyst deactivatingagent is introduced into the polymerization reactor system downstream ofthe polymerization reactor to completely terminate the polymerizationreaction.

Embodiment 4

The method defined in embodiment 1, wherein a process variable ismonitored to detect an undesired condition in the polymerization reactorsystem, and when the undesired reaction condition has reached apredetermined critical level, the catalyst deactivating agent isintroduced into the polymerization reactor.

Embodiment 5

The method defined in any one of the preceding embodiments, the methodfurther comprising:

a step of discontinuing the introducing of the transition metal-basedcatalyst system into the polymerization reactor before, during, or afterthe step of introducing the catalyst deactivating agent into thepolymerization reactor or polymerization reactor system;

a step of discontinuing the introducing of the olefin monomer into thepolymerization reactor before, during, or after the step of introducingthe catalyst deactivating agent into the polymerization reactor orpolymerization reactor system; or

both.

Embodiment 6

The method defined in embodiment 1, wherein:

Step (i) comprises:

-   -   (A) introducing a first transition metal-based catalyst system,        a first olefin monomer, and optionally a first olefin comonomer        into a polymerization reactor in the polymerization reactor        system;        Step (ii) comprises:    -   (B) contacting the first transition metal-based catalyst system        with the first olefin monomer and the optional first olefin        comonomer under polymerization conditions to produce a first        olefin polymer; the method further comprising:    -   (C) discontinuing the introducing of the first transition        metal-based catalyst system into the polymerization reactor        before, during, or after step (iii) of introducing the catalyst        deactivating agent into the polymerization reactor; and    -   (D) introducing a second transition metal-based catalyst system        into the polymerization reactor and contacting the second        transition metal-based catalyst system with a second olefin        monomer and optionally a second olefin comonomer under        polymerization conditions to produce a second olefin polymer.

Embodiment 7

The method defined in any one of the preceding embodiments, wherein thetransition metal-based catalyst system comprises any transition metaldisclosed herein, for example, chromium, vanadium, titanium, zirconium,hafnium, or a combination thereof.

Embodiment 8

The method defined in any one of the preceding embodiments, wherein thetransition metal-based catalyst system is any transition metal-basedcatalyst system disclosed herein, for example, a chromium-based catalystsystem, a Ziegler-Natta based catalyst system, a metallocene-basedcatalyst system, and the like, or a combination thereof.

Embodiment 9

The method defined in any one of the preceding embodiments, wherein theolefin monomer is any olefin monomer disclosed herein, for example, aC₂-C₂₀ olefin, ethylene, propylene, etc.

Embodiment 10

The method defined in any one of the preceding embodiments, wherein theolefin monomer is ethylene.

Embodiment 11

The method defined in any one of the preceding embodiments, wherein theolefin monomer is ethylene and the olefin comonomer comprises any olefincomonomer disclosed herein, for example, propylene, 1-butene, 2-butene,3-methyl-1-butene, isobutylene, 1-pentene, 2-pentene,3-methyl-1-pentene, 4-methyl-1-pentene, 1-hexene, 2-hexene,3-ethyl-1-hexene, 1-heptene, 2-heptene, 3-heptene, 1-octene, 1-decene,styrene, or a mixture thereof.

Embodiment 12

The method defined in any one of the preceding embodiments, wherein theolefin monomer is ethylene and the olefin comonomer comprises 1-butene,1-hexene, 1-octene, or a mixture thereof.

Embodiment 13

The method defined in any one of the preceding embodiments, wherein thepolymerization reactor system comprises any reactor type disclosedherein, for example, a slurry reactor, a gas-phase reactor, a solutionreactor, or a combination thereof.

Embodiment 14

The method defined in any one of the preceding embodiments, wherein thepolymerization reactor system comprises two or more reactors.

Embodiment 15

The method defined in any one of the preceding embodiments, wherein thecatalyst deactivating agent is introduced into the polymerizationreactor or polymerization reactor system at an amount in any range ofweight ratios of the catalyst deactivating agent to the transition metalin the transition metal-based catalyst system disclosed herein, forexample, in a range from 0.001:1 to 1000:1, from 0.01:1 to 1000:1, from0:1:1 to 500:1, from 1:1 to 100:1, etc.

Embodiment 16

The method defined in any one of the preceding embodiments, wherein thestep of introducing the catalyst deactivating agent into thepolymerization reactor or polymerization reactor system reduces thecatalyst activity of the transition metal-catalyst system by anypercentage amount disclosed herein, for example, at least 50%, at least90%, etc.

Embodiment 17

The method defined in any one of the preceding embodiments, wherein thestep of introducing the catalyst deactivating agent into thepolymerization reactor or polymerization reactor system reduces theproduction rate of the olefin polymer by any percentage amount disclosedherein, for example, at least 50%, at least 90%, etc.

Embodiment 18

The method defined in any one of the preceding embodiments, wherein thestep of introducing the catalyst deactivating agent into thepolymerization reactor or polymerization reactor system reduces thecatalyst activity of the transition metal-catalyst system by anypercentage amount disclosed herein in any maximum time period disclosedherein, for example, reducing the catalyst activity by at least 95% in atime period of less than 1 minute.

Embodiment 19

The method defined in any one of the preceding embodiments, wherein thestep of introducing the catalyst deactivating agent into thepolymerization reactor or polymerization reactor system reduces theproduction rate of the olefin polymer by any percentage amount disclosedherein in any maximum time period disclosed herein, for example,reducing the production rate by at least 95% in a time period of lessthan 1 minute.

Embodiment 20

A composition comprising:

a hydrocarbon solvent having from 3 to 18 carbon atoms; and

a catalyst deactivating agent comprising a natural source oil, asiloxane, or a combination thereof.

Embodiment 21

The composition defined in embodiment 20, wherein the hydrocarbonsolvent comprises any hydrocarbon solvent having from 3 to 18 carbonatoms disclosed herein, for example, propane, isobutane, n-butane,n-pentane, isopentane, neopentane, n-hexane, heptane, octane,cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane,benzene, toluene, xylene, ethylbenzene, or a mixture thereof.

Embodiment 22

The composition defined in embodiment 20 or 21, wherein the weight ratioof the hydrocarbon solvent to the catalyst deactivating agent in thecomposition is any range of weight ratios disclosed herein, for example,from about 1000:1 to about 1:100, or from about 500:1 to about 1:50.

Embodiment 23

The method or composition defined in any one of the precedingembodiments, wherein the catalyst deactivating agent has a boiling pointgreater than any minimum boiling point temperature or in any boilingpoint range disclosed herein, for example, a boiling point of at least100° C., or a boiling point of at least 120° C.

Embodiment 24

The method or composition defined in any one of the precedingembodiments, wherein the catalyst deactivating agent is miscible withany C₃ to C₁₀ hydrocarbon solvent disclosed herein.

Embodiment 25

The method or composition defined in any one of the precedingembodiments, wherein the catalyst deactivating agent is miscible withpropane, cyclohexane, isobutane, n-butane, n-pentane, isopentane,neopentane, n-hexane, or benzene, or a mixture thereof.

Embodiment 26

The method or composition defined in any one of the precedingembodiments, wherein the catalyst deactivating agent is soluble in anyC₃ to C₁₀ hydrocarbon solvent disclosed herein.

Embodiment 27

The method or composition defined in any one of the precedingembodiments, wherein the catalyst deactivating agent is soluble inpropane, cyclohexane, isobutane, n-butane, n-pentane, isopentane,neopentane, n-hexane, or benzene, or a mixture thereof.

Embodiment 28

The method or composition defined in any one of the precedingembodiments, wherein the catalyst deactivating agent is a liquidthroughout any range of temperatures disclosed herein, for example, aliquid throughout the temperature range of 20° C. to 80° C., or a liquidthroughout the temperature range of −20° C. to 100° C.

Embodiment 29

The method or composition defined in any one of the precedingembodiments, wherein the catalyst deactivating agent comprises a naturalsource oil.

Embodiment 30

The method or composition defined in any one of the precedingembodiments, wherein the catalyst deactivating agent comprises a naturalsource oil, and wherein the natural source oil comprises a tallow oil,an olive oil, a peanut oil, a castor bean oil, a sunflower oil, a sesameoil, a poppy seed oil, a palm oil, an almond seed oil, a hazelnut oil, arapeseed oil, a canola oil, a soybean oil, a corn oil, a safflower oil,a cottonseed oil, a camelina oil, a flaxseed oil, a walnut oil, or anycombination thereof.

Embodiment 31

The method or composition defined in any one of the precedingembodiments, wherein the catalyst deactivating agent comprises a naturalsource oil, and wherein the natural source oil comprises a soybean oil,a corn oil, a canola oil, a castor bean oil, or a combination thereof.

Embodiment 32

The method or composition defined in any one of the precedingembodiments, wherein the catalyst deactivating agent comprises a naturalsource oil, and wherein the natural source oil is a corn oil.

Embodiment 33

The method or composition defined in any one of embodiments 1-28,wherein the catalyst deactivating agent comprises a siloxane.

Embodiment 34

The method or composition defined in any one of embodiments 1-28,wherein the catalyst deactivating agent comprises a siloxane, andwherein the siloxane has the formula:

wherein:

-   -   each R independently is a C₁ to C₁₈ hydrocarbyl group; and    -   n is an integer greater than or equal to 2.

Embodiment 35

The method or composition defined in embodiment 34, wherein each Rindependently is a C₁ to C₈ alkyl group, a C₂ to C₈ alkenyl group, a C₆to C₁₀ aryl group, or a C₇ to C₁₀ aralkyl group.

Embodiment 36

The method or composition defined in embodiment 34, wherein each Rindependently is methyl, ethyl, propyl, butyl, phenyl, or benzyl.

Embodiment 37

The method or composition defined in embodiment 34, wherein each R ismethyl.

Embodiment 38

The method or composition defined in any one of embodiments 34-37,wherein n is an integer in any range of integers disclosed herein, forexample, from 2 to 900, from 3 to 500, or from 5 to 250.

Embodiment 39

The method or composition defined in any one of embodiments 33-38,wherein the siloxane has a viscosity less than any maximum viscosity orin any range of viscosities disclosed herein, for example, less than10,000 cSt at 25° C., in a range from 2 to 5,000 cSt at 25° C., or in arange from 2 to 500 cSt at 25° C.

Embodiment 40

The method or composition defined in any one of embodiments 33-39,wherein the siloxane is any siloxane material disclosed herein, forexample, hexamethyldisiloxane, octamethyltrisiloxane,tetramethyltetraphenyltrisiloxane, trimethylpentaphenyltrisiloxane,decamethyltetrasiloxane, octamethylcyclotetrasiloxane,decamethylcyclopentasiloxane, dodecamethylpentasiloxane,dodecamethylcyclohexasiloxane, a dimethyl-diphenylsiloxane, aphenylmethylsiloxane-dimethylsiloxane, a phenylmethylsiloxane, apolydimethylsiloxane, and the like, or any combination thereof.

Embodiment 41

The method or composition defined in any one of embodiments 33-40,wherein the siloxane is a polydimethylsiloxane.

We claim:
 1. A method of controlling a polymerization reaction in apolymerization reactor system, the method comprising: (i) introducing atransition metal-based catalyst system, an olefin monomer, andoptionally an olefin comonomer into a polymerization reactor within thepolymerization reactor system; (ii) contacting the transitionmetal-based catalyst system with the olefin monomer and the optionalolefin comonomer under polymerization conditions to produce an olefinpolymer; and (iii) introducing a catalyst deactivating agent into thepolymerization reactor to partially or completely terminate thepolymerization reaction in the polymerization reactor, wherein: thecatalyst deactivating agent comprises a natural source oil; the catalystdeactivating agent is introduced into the polymerization reactor at aweight ratio of the catalyst deactivating agent to the transition metalin the transition metal-based catalyst system in a range from 0.001:1 to1000:1; and the transition metal-based catalyst system does not comprisean alkylaluminum co-catalyst.
 2. The method of claim 1, wherein thenatural source oil comprises a tallow oil, an olive oil, a peanut oil, acastor bean oil, a sunflower oil, a sesame oil, a poppy seed oil, a palmoil, an almond seed oil, a hazelnut oil, a rapeseed oil, a canola oil, asoybean oil, a corn oil, a safflower oil, a cottonseed oil, a camelinaoil, a flaxseed oil, a walnut oil, or any combination thereof.
 3. Themethod of claim 2, wherein the natural source oil comprises a soybeanoil, a corn oil, a canola oil, a castor bean oil, or a combinationthereof.
 4. The method of claim 3, wherein the natural source oil is acorn oil.
 5. The method of claim 1, wherein the catalyst deactivatingagent: has a boiling point of at least 100° C.; is miscible with a C₃ toC₁₀ hydrocarbon solvent; and is a liquid throughout a temperature rangeof 20° C. to 80° C.
 6. The method of claim 1, wherein the catalystdeactivating agent: has a boiling point of at least 120° C.; is misciblewith propane, cyclohexane, isobutane, n-butane, n-pentane, isopentane,neopentane, n-hexane, or benzene, or a mixture thereof; and is a liquidthroughout a temperature range of −20° C. to 100° C.
 7. The method ofclaim 1, wherein the transition metal-based catalyst system compriseschromium, vanadium, titanium, zirconium, hafnium, or a combinationthereof.
 8. The method of claim 1, wherein the transition metal-basedcatalyst system is a chromium-based catalyst system, a Ziegler-Nattabased catalyst system, a metallocene-based catalyst system, or acombination thereof.
 9. The method of claim 1, wherein the olefinmonomer is a C₂-C₂₀ olefin.
 10. The method of claim 1, wherein theolefin monomer is ethylene and the olefin comonomer comprises propylene,1-butene, 2-butene, 3-methyl-1-butene, isobutylene, 1-pentene,2-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-hexene, 2-hexene,3-ethyl-1-hexene, 1-heptene, 2-heptene, 3-heptene, 1-octene, 1-decene,styrene, or a mixture thereof.
 11. The method of claim 1, wherein thepolymerization reactor system comprises a slurry reactor, a gas-phasereactor, a solution reactor, or a combination thereof.
 12. The method ofclaim 1, wherein the catalyst deactivating agent is introduced into thepolymerization reactor at a weight ratio of the catalyst deactivatingagent to the transition metal in the transition metal-based catalystsystem in a range from 0.1:1 to 100:1.
 13. The method of claim 1,wherein the step of introducing the catalyst deactivating agent into thepolymerization reactor: reduces the catalyst activity of the transitionmetal-catalyst system by at least 50%; reduces the production rate ofthe olefin polymer by at least 50%; or both.
 14. The method of claim 1,further comprising: a step of discontinuing the introducing of thetransition metal-based catalyst system into the polymerization reactorbefore, during, or after the step of introducing the catalystdeactivating agent into the polymerization reactor; a step ofdiscontinuing the introducing of the olefin monomer into thepolymerization reactor before, during, or after the step of introducingthe catalyst deactivating agent into the polymerization reactor; orboth.
 15. The method of claim 1, wherein the step of introducing thecatalyst deactivating agent into the polymerization reactor: reduces thecatalyst activity of the transition metal-catalyst system by at least95% in a time period of less than 1 minute; reduces the production rateof the olefin polymer by at least 95% in a time period of less than 1minute; or both.
 16. The method of claim 1, wherein a process variableis monitored to detect an undesired condition in the polymerizationreactor system, and introducing the catalyst deactivating agentcomprises introducing the catalyst deactivating agent into thepolymerization reactor when the undesired condition has reached apredetermined critical level.
 17. A method of controlling apolymerization reaction in a polymerization reactor system, the methodcomprising: (i) introducing a transition metal-based catalyst system, anolefin monomer, and optionally an olefin comonomer into a polymerizationreactor within the polymerization reactor system; (ii) contacting thetransition metal-based catalyst system with the olefin monomer and theoptional olefin comonomer under polymerization conditions to produce anolefin polymer; and (iii) introducing a catalyst deactivating agentcomprising a natural source oil into the polymerization reactor topartially or completely terminate the polymerization reaction in thepolymerization reactor; wherein: the natural source oil comprises asoybean oil, a corn oil, a canola oil, a castor bean oil, or acombination thereof; the transition metal-based catalyst systemcomprises chromium, vanadium, titanium, zirconium, hafnium, or acombination thereof; and the catalyst deactivating agent is introducedinto the polymerization reactor at a weight ratio of the catalystdeactivating agent to the transition metal in the transition metal-basedcatalyst system in a range from 0.001:1 to 1000:1.
 18. The method ofclaim 17, wherein the transition metal-based catalyst system is achromium-based catalyst system, a Ziegler-Natta based catalyst system, ametallocene-based catalyst system, or a combination thereof.
 19. Themethod of claim 17, wherein the olefin monomer is a C₂-C₂₀ olefin. 20.The method of claim 17, wherein the transition metal-based catalystsystem is contacted with ethylene and the olefin comonomer, and whereinthe olefin comonomer comprises 1-butene, 1-hexene, 1-octene, or amixture thereof.
 21. The method of claim 17, wherein the polymerizationreactor system comprises a slurry reactor, a gas-phase reactor, asolution reactor, or a combination thereof.
 22. The method of claim 17,wherein the catalyst deactivating agent is introduced into thepolymerization reactor at a weight ratio of the catalyst deactivatingagent to the transition metal in the transition metal-based catalystsystem in a range from 0.5:1 to 50:1.